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Virtual Environment Computer Simulations to Support Human Factors Engineering and Operations Analysis for the RLV Program

The Army-NASA Virtual Innovations Laboratory (ANVIL) was recently created to provide virtual reality tools for performing Human Engineering and operations analysis for both NASA and the Army. The author's summer research project consisted of developing and refining these tools for NASA's Reusable Launch Vehicle (RLV) program. Several general simulations were developed for use by the ANVIL for the evaluation of the X34 Engine Changeout procedure. These simulations were developed with the software tool dVISE 4.0.0 produced by Division Inc. All software was run on an SGI Indigo2 High Impact. This paper describes the simulations, various problems encountered with the simulations, other summer activities, and possible work for the future. We first begin with a brief description of virtual reality systems.

Lunsford, Myrtis Leigh

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

Second Generation RLV Program

During the time period covered by this report, SAIC: 1) Continued to develop and assess processes and approaches that can be applied to Second Generation Reuseable Launch Vehicles (RLV) technologies prioritization. An approach based on the use of analytic Saaty scale functions has been defined and is being investigated. 2) Planned and facilitated technologies prioritization workshops, supported development of systems program algorithms based on the concept of influence diagramming, and assessment of analogies between aircraft and space systems developments. 3) Video interviews held with X-37 personnel at Dryden. The CD-ROM is being concluded and a near-final review disc is expected soon. 4) CD-ROMS were produced by Engineered Multimedia, Inc. (EMI) under subcontract to SAIC. These two CD-ROM products, "Microgravity" and "New Horizons", were delivered to MSFS technical representatives at a briefing at SAID on January 18, 2001. 5) Presentation brochure, "Aviation/Space Analog Team Interim Report" was provided to Space Propulsion Synergy Team (SPST) members and to NASA personnel. Wrap-up of effort will be a mid-April briefing to both MSFC and the full SPST membership. Support to Phase 2 of CCPD ends 3/31/01. Phase 3 continuation effort planned with emphasis on technical info content. 6) Recommended that eliminating the B-52 flights of the X-37 in favor of alternate approached be evaluated. Discovered that a required change to the thruster valves of the X-37 had not been made. Repair work continues on the lower fuselage section of the X-37, in the areas that experienced core collapse. The currently catalogued potential weight increases and decreases are about equal, but this does not include the impact of the cable weight underestimate reported earlier. The CFD for RCS testing correlates well with the wind tunnel data. 7) The Level IV CCB approved SCN-4 to the MC-1 Engine SPecification. Approved changes have been incorporated into the specification, and Revision D has been released to the Repository. Billy Gonterman, SAIC, traveled to SSC to perform a five-day readiness assessment on the progress of facilities activation. Implemented modifications to the MC-1 Engine TPA Component Database. 8) Replaced 25 Combined-Cycle Propulsion Database (CCPD) documents; modified the low-on screen to include a direct email link for user contact; prepared a summary presentation of current and proposed tasks.

Laue, Jay

Support to 2nd Generation RLV Propulsion Project Office

In this final report regarding support to the second generation RLV (Reusable Launch Vehicle) propulsion project office, a list of tasks accomplished is presented. During this period, Lee & Associates, LLC participated in numerous Systems Requirements Reviews (SRR) related to the Cobra development program.

Lee, Thomas J.

Main Engine Prototype Development for 2nd Generation RLV RS-83

This presentation reports on the NASA project to develop a prototype for RS-83 engine designed for use on reusable launch vehicles (RLV). Topics covered include: program objectives, overview schedule, organizational chart, integrated systems engineering processes, requirement analysis, catastrophic engine loss, maintainability analysis tools, and prototype design analysis.

John Vilja

Advanced Control Surface Seal Development at NASA GRC for 3rd Generation RLV

NASA's Glenn Research Center (GRC) is developing advanced control surface seal technologies for the 3rd Generation RLV program. GRC has designed several new test rigs to simulate the temperatures, pressures, and scrubbing conditions that seals would have to endure during service. A hot compression test rig and hot scrub test rig are being developed to perform tests at temperatures up to 3000 F. Another new test rig allows simultaneous seal flow and scrub tests at room temperature to evaluate changes in seal performance with scrubbing. High temperature ceramic preloading devices are being developed and evaluated as ways to improve seal resiliency.

Dunlap, Patrick H., Jr.

Composite Development and Applications for RLV Tankage

The development of polymer composite cryogenic tanks is a critical step in creating the next generation of launch vehicles. Future launch vehicles need to minimize the gross liftoff weight (GLOW), which is possible due to the 28%-41% reduction in weight that composite materials can provide over current aluminum technology. The development of composite cryogenic tanks, feedlines, and unpressurized structures are key enabling technologies for performance and cost enhancements for Reusable Launch Vehicles (RLVs). The technology development of composite tanks has provided direct and applicable data for feedlines, unpressurized structures, material compatibility, and cryogenic fluid containment for highly loaded complex structures and interfaces. All three types of structure have similar material systems, processing parameters, scaling issues, analysis methodologies, NDE development, damage tolerance, and repair scenarios. Composite cryogenic tankage is the most complex of the 3 areas and provides the largest breakthrough in technology. A building block approach has been employed to bring this family of difficult technologies to maturity. This approach has built up composite materials, processes, design, analysis and test methods technology through a series of composite test programs beginning with the NASP program to meet aggressive performance goals for reusable launch vehicles. In this paper, the development and application of advanced composites for RLV use is described.

Wright, Richard J.

Third Generation RLV Structural Seal Development Programs at NASA GRC

NASA is currently developing technologies for the 3rd Generation Reusable Launch Vehicle (RLV) that is being designed to enter service around the year 2025. In particular, NASA's Glenn Research Center (GRC) is working on advanced high temperature structural seal designs including propulsion system and control surface seals. Propulsion system seals are required along the edges of movable panels in advanced engines, while control surface seals seal the edges and hinge lines of movables flaps and elevons on the vehicle. The overall goal is to develop reusable, resilient seals capable of operating at temperatures up to 2000 F. High temperature seal preloading devices (e.g., springs) are also being evaluated as a means of improving seal resiliency. In order to evaluate existing and potential new seal designs, GRC has designed and is installing several new test rigs capable of simulating the types of conditions that the seals would endure during service including temperatures, pressures, and scrubbing. Two new rigs, the hot compression test rig and the hot scrub test rig, will be used to perform seal compression and scrub tests for many cycles at temperatures up to 3000 F. Another new test rig allows simultaneous flow and scrub tests to be performed on the seals at room temperature to evaluate how the flow blocking performance of the seals varies as they accumulate damage during scrubbing. This presentation will give an overview of these advanced seal development efforts.

Dunlap, Patrick H., Jr.

Adaptive grid methods for RLV environment assessment and nozzle analysis

Rapid access to highly accurate data about complex configurations is needed for multi-disciplinary optimization and design. In order to efficiently meet these requirements a closer coupling between the analysis algorithms and the discretization process is needed. In some cases, such as free surface, temporally varying geometries, and fluid structure interaction, the need is unavoidable. In other cases the need is to rapidly generate and modify high quality grids. Techniques such as unstructured and/or solution-adaptive methods can be used to speed the grid generation process and to automatically cluster mesh points in regions of interest. Global features of the flow can be significantly affected by isolated regions of inadequately resolved flow. These regions may not exhibit high gradients and can be difficult to detect. Thus excessive resolution in certain regions does not necessarily increase the accuracy of the overall solution. Several approaches have been employed for both structured and unstructured grid adaption. The most widely used involve grid point redistribution, local grid point enrichment/derefinement or local modification of the actual flow solver. However, the success of any one of these methods ultimately depends on the feature detection algorithm used to determine solution domain regions which require a fine mesh for their accurate representation. Typically, weight functions are constructed to mimic the local truncation error and may require substantial user input. Most problems of engineering interest involve multi-block grids and widely disparate length scales. Hence, it is desirable that the adaptive grid feature detection algorithm be developed to recognize flow structures of different type as well as differing intensity, and adequately address scaling and normalization across blocks. These weight functions can then be used to construct blending functions for algebraic redistribution, interpolation functions for unstructured grid generation, forcing functions to attract/repel points in an elliptic system, or to trigger local refinement, based upon application of an equidistribution principle. The popularity of solution-adaptive techniques is growing in tandem with unstructured methods. The difficultly of precisely controlling mesh densities and orientations with current unstructured grid generation systems has driven the use of solution-adaptive meshing. Use of derivatives of density or pressure are widely used for construction of such weight functions, and have been proven very successful for inviscid flows with shocks. However, less success has been realized for flowfields with viscous layers, vortices or shocks of disparate strength. It is difficult to maintain the appropriate mesh point spacing in the various regions which require a fine spacing for adequate resolution. Mesh points often migrate from important regions due to refinement of dominant features. An example of this is the well know tendency of adaptive methods to increase the resolution of shocks in the flowfield around airfoils, but in the incorrect location due to inadequate resolution of the stagnation region. This problem has been the motivation for this research.

Thornburg, Hugh J.

Real-Time Sensor Validation, Signal Reconstruction, and Feature Detection for an RLV Propulsion Testbed

A real-time system for validating sensor health has been developed in support of the reusable launch vehicle program. This system was designed for use in a propulsion testbed as part of an overall effort to improve the safety, diagnostic capability, and cost of operation of the testbed. The sensor validation system was designed and developed at the NASA Lewis Research Center and integrated into a propulsion checkout and control system as part of an industry-NASA partnership, led by Rockwell International for the Marshall Space Flight Center. The system includes modules for sensor validation, signal reconstruction, and feature detection and was designed to maximize portability to other applications. Review of test data from initial integration testing verified real-time operation and showed the system to perform correctly on both hard and soft sensor failure test cases. This paper discusses the design of the sensor validation and supporting modules developed at LeRC and reviews results obtained from initial test cases.

Jankovsky, Amy L.

Virtual Environment User Interfaces to Support RLV and Space Station Simulations in the ANVIL Virtual Reality Lab

Several virtual reality I/O peripherals were successfully configured and integrated as part of the author's 1997 Summer Faculty Fellowship work. These devices, which were not supported by the developers of VR software packages, use new software drivers and configuration files developed by the author to allow them to be used with simulations developed using those software packages. The successful integration of these devices has added significant capability to the ANVIL lab at MSFC. In addition, the author was able to complete the integration of a networked virtual reality simulation of the Space Shuttle Remote Manipulator System docking Space Station modules which was begun as part of his 1996 Fellowship. The successful integration of this simulation demonstrates the feasibility of using VR technology for ground-based training as well as on-orbit operations.

Dumas, Joseph D., II

Durability Demonstration of Small High Performance Rocket Thrusters for RLV Applications

The development of low cost, highly reusable rocket thrusters is essential for fulfilling NASA's commitment of providing economical space access. Results obtained from a recent sub-scale, high performance rocket thruster development and test program applied to a Rocket Based Combined Cycle engine have demonstrated rocket versatility and durability in over 678 tests at chamber pressures between 190 and 1930 psia using gaseous oxygen and gaseous hydrogen.

Neill, Todd

Advanced Electric Propulsion for RLV Launched Geosynchronous Spacecraft

Solar Electric Propulsion (SEP) when used for station keeping and final orbit insertion has been shown to increase a geostationary satellite's payload when launched by existing expendable launch vehicles. In the case of reusable launch vehicles or expendable launch vehicles where an upper stage is an expensive option, this methodology can be modified by using the existing on-board apogee chemical system to perform a perigee burn and then letting the electric propulsion system complete the transfer to geostationary orbit. The elimination of upper stages using on-board chemical and electric propulsion systems was thus examined for GEO spacecraft. Launch vehicle step-down from an Atlas IIAR to a Delta 7920 (no upper stage) was achieved using expanded on-board chemical tanks, 40 kW payload power for electric propulsion, and a 60 day elliptical to GEO SEP orbit insertion. Optimal combined chemical and electric trajectories were found using SEPSPOT. While Hall and ion thrusters provided launch vehicle step-down and even more payload for longer insertion times, NH3 arcjets had insufficient performance to allow launch vehicle step-down. Degradation levels were only 5% to 7% for launch step-down cases using advanced solar arrays. Results were parameterized to allow comparisons for future reusable launch vehicles. Results showed that for an 8 W/kg initial power/launch mass power density spacecraft, 50% to 100% more payload can be launched using this method.

Oleson, Steven

X-33 and RLV for the Future

A viewgraph presentation outlines the design and testing of the single stage to orbit vehicle, the X-33. The history and objectives of the program to build the X-33 are discussed, as well as the specifications for the spacecraft. Flight test results are given and future plans for a spaceport are discussed.

Bland, Jeffery D.

2nd Generation RLV Risk Reduction Definition Program: Pratt & Whitney Propulsion Risk Reduction Requirements Program (TA-3 & TA-4)

This is the final report and addresses all of the work performed on this program. Specifically, it covers vehicle architecture background, definition of six baseline engine cycles, reliability baseline (space shuttle main engine QRAS), and component level reliability/performance/cost for the six baseline cycles, and selection of 3 cycles for further study. This report further addresses technology improvement selection and component level reliability/performance/cost for the three cycles selected for further study, as well as risk reduction plans, and recommendation for future studies.

Matlock, Steve

RLV Turbine Performance Optimization

A task was developed at NASA/Marshall Space Flight Center (MSFC) to improve turbine aerodynamic performance through the application of advanced design and analysis tools. There are four major objectives of this task: 1) to develop, enhance, and integrate advanced turbine aerodynamic design and analysis tools; 2) to develop the methodology for application of the analytical techniques; 3) to demonstrate the benefits of the advanced turbine design procedure through its application to a relevant turbine design point; and 4) to verify the optimized design and analysis with testing. Final results of the preliminary design and the results of the two-dimensional (2D) detailed design of the first-stage vane of a supersonic turbine suitable for a reusable launch vehicle (R-LV) are presented. Analytical techniques for obtaining the results are also discussed.

Griffin, Lisa W.

2nd Generation Reusable Launch Vehicle (2G RLV)

This is a revised final report and addresses all of the work performed on this program. Specifically, it covers vehicle architecture background, definition of six baseline engine cycles, reliability baseline (space shuttle main engine QRAS), and component level reliability/performance/cost for the six baseline cycles, and selection of 3 cycles for further study. This report further addresses technology improvement selection and component level reliability/performance/cost for the three cycles selected for further study, as well as risk reduction plans, and recommendation for future studies.

Matlock, Steve