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NASA NTRS2006

Systems Integration Processes for NASA Ares I Crew Launch Vehicle

NASA's Exploration Initiative will require development of many new elements to constitute a robust system of systems. New launch vehicles are needed to place cargo and crew in stable Low Earth Orbit (LEO). This paper examines the systems integration processes NASA is utilizing to ensure integration and control of propulsion and nonpropulsion elements within NASA's Crew Launch Vehicle (CLV), now known as the Ares I. The objective of the Ares I is to provide the transportation capabilities to meet the Constellation Program requirements for delivering a Crew Exploration Vehicle (CEV) or other payload to LEO in support of the lunar and Mars missions. The Ares I must successfully provide this capability within cost and schedule, and with an acceptable risk approach. This paper will describe the systems engineering management processes that will be applied to assure Ares I Project success through complete and efficient technical integration. Discussion of technical review and management processes for requirements development and verification, integrated design and analysis, integrated simulation and testing, and the integration of reliability, maintainability and supportability (RMS) into the design will also be included. The Ares I Project is logically divided into elements by the major hardware groupings, and associated management, system engineering, and integration functions. The processes to be described herein are designed to integrate within these Ares I elements and among the other Constellation projects. Also discussed is launch vehicle stack integration (Ares I to CEV, and Ground and Flight Operations integration) throughout the life cycle, including integrated vehicle performance through orbital insertion, recovery of the first stage, and reentry of the upper stage. The processes for decomposing requirements to the elements and ensuring that requirements have been correctly validated, decomposed, and allocated, and that the verification requirements are properly defined to ensure that the system design meets requirements, will be discussed.

Taylor, James L.↗
NASA NTRS2007

Scientific Exploration of Near-Earth Objects via the Crew Exploration Vehicle

The concept of a crewed mission to a near-Earth object (NEO) has been previously analyzed several times in the past. A more in depth feasibility study has been sponsored by the Advanced Projects Office within NASA's Constellation Program to examine the ability of a Crew Exploration Vehicle (CEV) to support a mission to a NEO. The national mission profile would involve a crew of 2 or 3 astronauts on a 90 to 120 day mission, which would include a 7 to 14 day stay for proximity operations at the target NEO.

Abell, P. A.↗
NASA NTRS2007

Boeing Crew Exploration Vehicle Environmental Control and Life Support System Architecture Overview

The Boeing Company under the teaming agreement with the Northrop Grumman Systems Corporation and in compliance with the NASA Phase 1 contract, had the responsibilities for the CEV architecture development of the Environmental control and life support (ECLS) system under the NASA Phase 1 contract. The ECLS system was comprised of the various subsystems which provided for a shirt-sleeve habitable environment for crew to live and work in the crew module of the CEV. This architecture met the NASA requirements to ferry cargo and crew to ISS, and Lunar sortie missions, with extensibility to long duration missions to Moon and MARS. This paper provides a summary overview of the CEV ECLS subsystems which was proposed in compliance with the contract activities.

Saiidi, Mo↗
NASA NTRS2007

Crew Exploration Vehicle Environmental Control and Life Support Development Status

The Crew Exploration Vehicle (CEV) is the first crew transport vehicle to be developed by the National Aeronautics and Space Administration (NASA) in the last thirty years. The CEV is being developed to transport the crew safely from the Earth to the Moon and back again. This year, the prime contractor has been selected, requirements have been refined, and development areas are being pursued. The Environmental Control and Life Support (ECLS) system, which includes the life support and active thermal control systems, is moving one year closer to performing on orbit.

Lewis, John F.↗
NASA NTRS2007

Crew Exploration Vehicle Launch Abort System Flight Test Overview

The Constellation program is an organization within NASA whose mission is to create the new generation of spacecraft that will replace the Space Shuttle after its planned retirement in 2010. In the event of a catastrophic failure on the launch pad or launch vehicle during ascent, the successful use of the launch abort system will allow crew members to escape harm. The Flight Test Office is the organization within the Constellation project that will flight-test the launch abort system on the Orion crew exploration vehicle. The Flight Test Office has proposed six tests that will demonstrate the use of the launch abort system. These flight tests will be performed at the White Sands Missile Range in New Mexico and are similar in nature to the Apollo Little Joe II tests performed in the 1960s. An overview of the launch abort system flight tests for the Orion crew exploration vehicle is given. Details on the configuration of the first pad abort flight test are discussed. Sample flight trajectories for two of the six flight tests are shown.

Williams-Hayes, Peggy S.↗
NASA NTRS2007

Preliminary Structural Sizing and Alternative Material Trade Study of CEV Crew Module

This paper presents the results of a preliminary structural sizing and alternate material trade study for NASA s Crew Exploration Vehicle (CEV) Crew Module (CM). This critical CEV component will house the astronauts during ascent, docking with the International Space Station, reentry, and landing. The alternate material design study considers three materials beyond the standard metallic (aluminum alloy) design that resulted from an earlier NASA Smart Buyer Team analysis. These materials are graphite/epoxy composite laminates, discontinuously reinforced SiC/Al (DRA) composites, and a novel integrated panel material/concept known as WebCore. Using the HyperSizer (Collier Research and Development Corporation) structural sizing software and NASTRAN finite element analysis code, a comparison is made among these materials for the three composite CM concepts considered by the 2006 NASA Engineering and Safety Center Composite Crew Module project.

Bednarcyk, Brett A.↗
NASA NTRS2007

Analytical Approach for Estimating Preliminary Mass of ARES I Crew Launch Vehicle Upper Stage Structural Components

In January 2004, President Bush gave the National Aeronautics and Space Administration (NASA) a vision for Space Exploration by setting our sight on a bold new path to go back to the Moon, then to Mars and beyond. In response to this vision, NASA started the Constellation Program, which is a new exploration launch vehicle program. The primary mission for the Constellation Program is to carry out a series of human expeditions ranging from Low Earth Orbit to the surface of Mars and beyond for the purposes of conducting human exploration of space, as specified by the Vision for Space Exploration (VSE). The intent is that the information and technology developed by this program will provide the foundation for broader exploration activities as our operational experience grows. The ARES I Crew Launch Vehicle (CLV) has been designated as the launch vehicle that will be developed as a "first step" to facilitate the aforementioned human expeditions. The CLV Project is broken into four major elements: First Stage, Upper Stage Engine, Upper Stage (US), and the Crew Exploration Vehicle (CEV). NASA's Marshall Space Flight Center (MSFC) is responsible for the design of the CLV and has the prime responsibility to design the upper stage of the vehicle. The US is the second propulsive stage of the CLV and provides CEV insertion into low Earth orbit (LEO) after separation from the First Stage of the Crew Launch Vehicle. The fully integrated Upper Stage is a mix of modified existing heritage hardware (J-2X Engine) and new development (primary structure, subsystems, and avionics). The Upper Stage assembly is a structurally stabilized cylindrical structure, which is powered by a single J-2X engine which is developed as a separate Element of the CLV. The primary structure includes the load bearing liquid hydrogen (LH2) and liquid oxygen (LOX) propellant tanks, a Forward Skirt, the Intertank structure, the Aft Skirt and the Thrust Structure. A Systems Tunnel, which carries fluid and electrical power functions to other Elements of the CLV, is included as secondary structure. The MSFC has an overall responsibility for the integrated US element as well as structural design an thermal control of the fuel tanks, intertank, interstage, avionics, main propulsion system, Reaction Control System (RCS) for both the Upper Stage and the First Stage. MSFC's Spacecraft and Vehicle Department, Structural and Analysis Design Division is developing a set of predicted mass of these elements. This paper details the methodology, criterion and tools used for the preliminary mass predictions of the upper stage structural assembly components. In general, weight of the cylindrical barrel sections are estimated using the commercial code Hypersizer, whereas, weight of the domes are developed using classical solutions. HyperSizer is software that performs automated structural analysis and sizing optimization based on aerospace methods for strength, stability, and stiffness. Analysis methods range from closed form, traditional hand calculations repeated every day in industry to more advanced panel buckling algorithms. Margin-of-safety reporting for every potential failure provides the engineer with a powerful insight into the structural problem. Optimization capabilities include finding minimum weight panel or beam concepts, material selections, cross sectional dimensions, thicknesses, and lay-ups from a library of 40 different stiffened and sandwich designs and a database of composite, metallic, honeycomb, and foam materials. Multiple different concepts (orthogrid, isogrid, and skin stiffener) were run for multiple loading combinations of ascent design load with and with out tank pressure as well as proof pressure condition. Subsequently, selected optimized concept obtained from Hypersizer runs was translated into a computer aid design (CAD) model to account for the wall thickness tolerance, weld land etc for developing the most probable weight of the components. The flow diram summarizes the analysis steps used in developing these predicted mass.

Aggarwal, Pravin↗
NASA NTRS2007

Optimization of Crew Shielding Requirement in Reactor-Powered Lunar Surface Missions

On the surface of the moon -and not only during heightened solar activities- the radiation environment As such that crew protection will be required for missions lasting in excess of six months. This study focuses on estimating the optimized crew shielding requirement for lunar surface missions with a nuclear option. Simple, transport-simulation based dose-depth relations of the three (galactic, solar, and fission) radiation sources am employed in a 1-dimensional optimization scheme. The scheme is developed to estimate the total required mass of lunar-regolith separating reactor from crew. The scheme was applied to both solar maximum and minimum conditions. It is shown that savings of up to 30% in regolith mass can be realized. It is argued, however, that inherent variation and uncertainty -mainly in lunar regolith attenuation properties in addition to the radiation quality factor- can easily defeat this and similar optimization schemes.

Barghouty, Abdulnasser F.↗
NASA NTRS2007

Optimization of Crew Shielding Requirement in Reactor-Powered Lunar Surface Missions

On the surface of the moon and not only during heightened solar activities the radiation environment is such that crew protection will be required for missions lasting in excess of six months. This study focuses on estimating the optimized crew shielding requirement for lunar surface missions with a nuclear option. Simple, transport-simulation based dose-depth relations of the three radiation sources (galactic, solar, and fission) are employed in a one-dimensional optimization scheme. The scheme is developed to estimate the total required mass of lunar regolith separating reactor from crew. The scheme was applied to both solar maximum and minimum conditions. It is shown that savings of up to 30% in regolith mass can be realized. It is argued, however, that inherent variation and uncertainty mainly in lunar regolith attenuation properties in addition to the radiation quality factor can easily defeat this and similar optimization schemes.

Barghouty, A. F.↗
NASA NTRS2008

Orion Crew Member Injury Predictions during Land and Water Landings

A review of astronaut whole body impact tolerance is discussed for land or water landings of the next generation manned space capsule named Orion. LS-DYNA simulations of Orion capsule landings are performed to produce a low, moderate, and high probability of injury. The paper evaluates finite element (FE) seat and occupant simulations for assessing injury risk for the Orion crew and compares these simulations to whole body injury models commonly referred to as the Brinkley criteria. The FE seat and crash dummy models allow for varying the occupant restraint systems, cushion materials, side constraints, flailing of limbs, and detailed seat/occupant interactions to minimize landing injuries to the crew. The FE crash test dummies used in conjunction with the Brinkley criteria provides a useful set of tools for predicting potential crew injuries during vehicle landings.

Lawrence, Charles↗
NASA NTRS2008

International Space Station USOS Crew Quarters Development

The International Space Station (ISS) United States Operational Segment (USOS) currently provides a Temporary Sleep Station (TeSS) as crew quarters for one crewmember in the Laboratory Module. The Russian Segment provides permanent crew quarters (Kayutas) for two crewmembers in the Service Module. The TeSS provides limited electrical, communication, and ventilation functionality. A new permanent rack sized USOS ISS Crew Quarters (CQ) is being developed. Up to four CQs can be installed into the Node 2 element to increase the ISS crewmember size to six. The new CQs will provide private crewmember space with enhanced acoustic noise mitigation, integrated radiation reduction material, controllable airflow, communication equipment, redundant electrical systems, and redundant caution and warning systems. The rack sized CQ is a system with multiple crewmember restraints, adjustable lighting, controllable ventilation, and interfaces that allow each crewmember to personalize their CQ workspace. Providing an acoustically quiet and visually isolated environment, while ensuring crewmember safety, is critical for obtaining crewmember rest and comfort to enable long term crewmember performance. The numerous human factor, engineering, and program considerations during the concept, design, and prototyping are outlined in the paper.

Broyan, James Lee, Jr.↗
NASA NTRS2008

Integrated Software Systems for Crew Management During Extravehicular Activity in Planetary Terrain Exploration

Initial planetary explorations with the Apollo program had a veritable ground support army monitoring the safety and health of the 12 astronauts who performed lunar surface extravehicular activities (EVAs). Given the distances involved, this will not be possible on Mars. A spacesuit for Mars must be smart enough to replace that army. The next generation suits can do so using 2 software systems serving as virtual companions, LEGACI (Life support, Exploration Guidance Algorithm and Consumable Interrogator) and VIOLET (Voice Initiated Operator for Life support and Exploration Tracking). The system presented in this study integrates data inputs from a suite of sensors into the MIII suit s communications, avionics and informatics hardware for distribution to remote managers and data analysis. If successful, the system has application not only for Mars but for nearer term missions to the Moon, and the next generation suits used on ISS as well. Field tests are conducted to assess capabilities for next generation spacesuits at Johnson Space Center (JSC) as well as the Mars and Lunar analog (Devon Island, Canada). LEGACI integrates data inputs from a suite of noninvasive biosensors in the suit and the astronaut (heart rate, suit inlet/outlet lcg temperature and flowrate, suit outlet gas and dewpoint temperature, pCO2, suit O2 pressure, state vector (accelerometry) and others). In the Integrated Walkback Suit Tests held at NASA-JSC and the HMP tests at Devon Island, communication and informatics capabilities were tested (including routing by satellite from the suit at Devon Island to JSC in Houston via secure servers at VCU in Richmond, VA). Results. The input from all the sensors enable LEGACI to compute multiple independent assessments of metabolic rate, from which a "best" met rate is chosen based on statistical methods. This rate can compute detailed information about the suit, crew and EVA performance using test-derived algorithms. VIOLET gives LEGACI voice activation capability, allowing the crew to query the suit, and receive feedback and alerts that will lead to corrective action. LEGACI and VIOLET can also automatically control the astronaut's cooling and consumable use rate without crew input if desired. These findings suggest that non-invasive physiological and environmental sensors supported with data analysis can allow for more effective management of mission task performance during EVA. Integrated remote and local view of data metrics allow crewmember to receive real time feedback in synch with mission control in preventing performance shortcomings for EVA in exploration missions.

Kuznetz, Lawrence↗
NASA NTRS2008

Status, Plans and Initial Results for Ares I Crew Launch Vehicle Aerodynamics

Following the completion of NASA s Exploration Systems Architecture Study in August 2004 for the NASA Exploration Systems Mission Directorate (ESMD), the Ares Projects Office at the NASA Marshall Space Flight Center was assigned project management responsibilities for the design and development of the first vehicle in the architecture, the Ares I Crew Launch Vehicle (CLV), which will be used to launch astronauts to low earth orbit and rendezvous with either the International Space Station or the ESMD s earth departure stage for lunar or other future missions beyond low Earth orbit. The primary elements of the Ares I CLV project are the first stage, the upper stage, the upper stage engine, and vehicle integration. Within vehicle integration is an effort in integrated design and analysis which is comprised of a number of technical disciplines needed to support vehicle design and development. One of the important disciplines throughout the life of the project is aerodynamics. This paper will present the status, plans, and initial results of Ares I CLV aerodynamics as the project was preparing for the Ares I CLV Systems Requirements Review. Following a discussion of the specific interactions with other technical panels and a status of the current activities, the plans for aerodynamic support of the Ares I CLV until the initial crewed flights will be presented. Keywords: Ares I Crew Launch Vehicle, aerodynamics, wind tunnel testing, computational fluid dynamics

Huebner, Lawrence D.↗
NASA NTRS2008

The Use of a Vehicle Acceleration Exposure Limit Model and a Finite Element Crash Test Dummy Model to Evaluate the Risk of Injuries During Orion Crew Module Landings

A review of astronaut whole body impact tolerance is discussed for land or water landings of the next generation manned space capsule named Orion. LS-DYNA simulations of Orion capsule landings are performed to produce a low, moderate, and high probability of injury. The paper evaluates finite element (FE) seat and occupant simulations for assessing injury risk for the Orion crew and compares these simulations to whole body injury models commonly referred to as the Brinkley criteria. The FE seat and crash dummy models allow for varying the occupant restraint systems, cushion materials, side constraints, flailing of limbs, and detailed seat/occupant interactions to minimize landing injuries to the crew. The FE crash test dummies used in conjunction with the Brinkley criteria provides a useful set of tools for predicting potential crew injuries during vehicle landings.

Lawrence, Charles↗
NASA NTRS2008

The Manufacturing Process for the NASA Composite Crew Module Demonstration Structure

This paper will describe the approaches and methods selected in fabrication of a carbon composite demonstration structure for the Composite Crew Module (CCM) Program. The program is managed by the NASA Safety and Engineering Center with participants from ten NASA Centers and AFRL. Multiple aerospace contractors are participating in the design development, tooling and fabrication effort as well. The goal of the program is to develop an agency wide design team for composite habitable spacecraft. The specific goals for this development project are: a).To gain hands on experience in design, building and testing a composite crew module. b) To validate key assumptions by resolving composite spacecraft design details through fabrication and testing of hardware. This abstract is based on Preliminary Design data..The final design will continue to evolve through the fall of 2007 with fabrication mostly completed by conference date. From a structures perspective, the.CCM can be viewed as a pressure module with variable pressure time histories and a series of both impact and quasi-static, high intensity point, line, and area distributed loads. The portion of the overall space vehicle being designed and. fabricated by the CCM team is just the pressure module and primary loading points. The heaviest point loads are applied and distributed to the pressure module at.an aluminum Service Module/Alternate Launch Abort System (SM/ALAS) fittings and at Main and Drogue Chute fittings. Significant line loads with metal to metal impact is applied at.the Lids ring. These major external point and line loads as well as pressure impact loads (blast and water landing) are applied to the lobed floor though the reentry shield and crushable materials. The pressure module is divided into upper and lower. shells that mate together with a bonded belly band splice joint to create the completed structural assembly. The benefits of a split CCM far outweigh the risks of a joint. These benefits include lower tooling cost and less manufacturing risk. Assembly of the top and bottom halves of the pressure shell will allow access to the interior of the shell throughout remaining fabrication sequence and can also potentially permit extensive installation of equipment and .crew facilities prior to final assembly of the two shell halves. A Pi pre-form is a woven carbon composite material which is provided in pre-impregnated form and frozen for long term storage. The cross-section shape allows the top of the pi to be bonded to a flat or curved surface with a second flat plate composite section bonded between two upstanding legs of the Pi. One of the regions relying on the merits of the Pi pre-form is the backbone. All connections among plates of the backbone structure, including the upper flanges, and to the lobe base of the pressure shell are currently joined by Pi pre-forms. The intersection of backbone composite plates is formed by application of two Pi pre-forms, top flanges and lobed surfaces are bonded with one Pi pre-form. The process of applying the pre-impregnated pi-preform will be demonstrated to include important steps like surface preparation, forming, application of pressure dams, vacuum bagging for consolidation, and curing techniques. Chopped carbon fiber tooling was selected over other traditional metallic and carbon fiber tooling. The requirement of schedule and cost economy for a moderate reuse cure tool warranted composite tooling options. Composite tooling schedule duration of 18 weeks compared favorably against other metallic tooling including invar tooling. Composite tooling also shows significant cost savings over low CTE metallic options. The composite tooling options were divided into two groups and the final decision was based on the cost, schedule, tolerance, temperature, and reuse requirements.

Pelham, Larry↗
NASA NTRS2008

Orion Crew Member Injury Predictions during Land and Water Landings

A review of astronaut whole body impact tolerance is discussed for land or water landings of the next generation manned space capsule named Orion. LS-DYNA simulations of Orion capsule landings are performed to produce a low, moderate, and high probability of injury. The paper evaluates finite element (FE) seat and occupant simulations for assessing injury risk for the Orion crew and compares these simulations to whole body injury models commonly referred to as the Brinkley criteria. The FE seat and crash dummy models allow for varying the occupant restraint systems, cushion materials, side constraints, flailing of limbs, and detailed seat/occupant interactions to minimize landing injuries to the crew. The FE crash test dummies used in conjunction with the Brinkley criteria provides a useful set of tools for predicting potential crew injuries during vehicle landings.

Lawrence, Charles↗
NASA NTRS2008

Ares I-X Flight Test Vehicle Similitude to the Ares I Crew Launch Vehicle

The Ares I-X Flight Test Vehicle is the first in a series of flight test vehicles that will take the Ares I Crew Launch Vehicle design from development to operational capability. The test flight is scheduled for April 2009, relatively early in the Ares I design process so that data obtained from the flight can impact the design of Ares I before its Critical Design Review. Because of the short time frame (relative to new launch vehicle development) before the Ares I-X flight, decisions about the flight test vehicle design had to be made in order to complete analysis and testing in time to manufacture the Ares I-X vehicle hardware elements. This paper describes the similarities and differences between the Ares I-X Flight Test Vehicle and the Ares I Crew Launch Vehicle. Areas of comparison include the outer mold line geometry, aerosciences, trajectory, structural modes, flight control architecture, separation sequence, and relevant element differences. Most of the outer mold line differences present between Ares I and Ares I-X are minor and will not have a significant effect on overall vehicle performance. The most significant impacts are related to the geometric differences in Orion Crew Exploration Vehicle at the forward end of the stack. These physical differences will cause differences in the flow physics in these areas. Even with these differences, the Ares I-X flight test is poised to meet all five primary objectives and six secondary objectives. Knowledge of what the Ares I-X flight test will provide in similitude to Ares I as well as what the test will not provide is important in the continued execution of the Ares I-X mission leading to its flight and the continued design and development of Ares I.

Huebner, Lawrence D.↗
NASA NTRS2009

Crew Exploration Vehicle Environmental Control and Life Support Development Status

The Crew Exploration Vehicle (CEV) is the first crew transport vehicle to be developed by the National Aeronautics and Space Administration (NASA) in the last thirty years. The CEV is being developed to transport the crew safely from the Earth to the Moon and back again. This year, the vehicle continued to go through design refinements to reduce weight, meet requirements, and operate reliably. The design of the Orion Environmental Control and Life Support (ECLS) system, which includes the life support and active thermal control systems, is progressing through the design stage. This paper covers the Orion ECLS development from April 2008 to April 2009.

Lewis, John F.↗