SEARCH · Engineering Papers
Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.
Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.
We describe the computational implementation of an analytic, shape-based method for the design of low-thrust, gravity-assist trajectories. We also augment the method by allowing coast arcs to be patched with thrust arcs on the transfers between bodies.
The Space Launch System (SLS) Core Stage (CS) Thrust Vector Control (TVC) consists of four independent hydraulic systems. The SLS CS TVC system is comprised of 8 mechanical feedback Shuttle heritage Type III TVC actuators and four RS-25 engines, each attached to a Shuttle heritage gimbal block/bearing. Each hydraulic system nominally provides hydraulic power to one RS-25 engine and two actuators. Additionally, each system provides redundant control capability to one actuator on each of its neighboring systems. The RS-25 uses hydraulic power to control propellant valves, and the TVC actuators are used to move the engine in the pitch and yaw gimbal planes. The TVC system design leverages hardware from the Space Shuttle program as well as new hardware designed specifically for the Core Stage. The Space Shuttle heritage hardware directly reused on SLS includes the Orbiter TVC hydraulic servo-actuators (with two slight design modifications), the Orbiter hydraulic circulation pumps, the Orbiter gimbal block/bearing, and the Solid Rocket Booster hydraulic pumps. The Solid Rocket Booster APU turbines are powered by hot gas produced by a catalyzed hydrazine decomposition. The SLS Core Auxiliary Power Unit (CAPU) is derived from the Space Shuttle Orbiter Auxiliary Power Unit (APU); on the SLS Core Stage, the CAPU turbine is spun using cold gas tapped-off from the RS-25 to CS liquid hydrogen autogenous pressurization line. The remaining hardware in the TVC system (hydraulic Filter Manifold (FM), hydraulic Supply Accumulator (SA), hydraulic Return Accumulator (RA), Hydraulic Reservoir, Exhaust Gas Heat Exchanger (EGHE)) as well as the avionics providing control and telemetry (TVC Actuator Controller (TAC) and CAPU Controller (CAPUC) are new components developed for SLS. This paper is the first installment in a seven-paper series surveying the design, engineering, test validation, and flight performance of the Core Stage Thrust Vector Control system. In this paper, the overall design architecture of the CS TVC is presented, with a focus on the interfaces between the TVC actuators, the engines, their hydraulic power systems, and the avionics that provide commands from the SLS Vehicle Management (VM) software to effect stable and robust flight control for the integrated SLS launch vehicle.
The Space Launch System (SLS) Core Stage (CS) Thrust Vector Control (TVC) consists of four independent hydraulic systems. The SLS CS TVC system is comprised of 8 mechanical feedback Shuttle heritage Type III TVC actuators and four RS-25 engines, each attached to a Shuttle heritage gimbal block/bearing. Each hydraulic system nominally provides hydraulic power to one RS-25 engine and two actuators. Additionally, each system provides redundant control capability to one actuator on each of its neighboring systems. The RS-25 uses hydraulic power to control propellant valves, and the TVC actuators are used to move the engine in the pitch and yaw gimbal planes. The TVC system design leverages hardware from the Space Shuttle program as well as new hardware designed specifically for the Core Stage. The Space Shuttle heritage hardware directly reused on SLS includes the Orbiter TVC hydraulic servo-actuators (with two slight design modifications), the Orbiter hydraulic circulation pumps, the Orbiter gimbal block/bearing, and the Solid Rocket Booster hydraulic pumps. The Solid Rocket Booster APU turbines are powered by hot gas produced by a catalyzed hydrazine decomposition. The SLS Core Auxiliary Power Unit (CAPU) is derived from the Space Shuttle Orbiter Auxiliary Power Unit (APU); on the SLS Core Stage, the CAPU turbine is spun using cold gas tapped-off from the RS-25 to CS liquid hydrogen autogenous pressurization line. The remaining hardware in the TVC system (hydraulic Filter Manifold (FM), hydraulic Supply Accumulator (SA), hydraulic Return Accumulator (RA), Hydraulic Reservoir, Exhaust Gas Heat Exchanger (EGHE)) as well as the avionics providing control and telemetry (TVC Actuator Controller (TAC) and CAPU Controller (CAPUC) are new components developed for SLS. This paper is the first installment in a seven-paper series surveying the design, engineering, test validation, and flight performance of the Core Stage Thrust Vector Control system. In this paper, the overall design architecture of the CS TVC is presented, with a focus on the interfaces between the TVC actuators, the engines, their hydraulic power systems, and the avionics that provide commands from the SLS Vehicle Management (VM) software to effect stable and robust flight control for the integrated SLS launch vehicle.
The Space Launch System (SLS) Core Stage (CS) Thrust Vector Control (TVC) system is comprised of 8 mechanical feedback Shuttle heritage Type III TVC actuators and four RS-25 engines, each attached to a Shuttle heritage gimbal block/bearing. Two actuators are used to move each engine in two planes perpendicular to one another (i.e., pitch and yaw). The TVC system design leverages hardware from the Space Shuttle program as well as new hardware designed specifically for the Core Stage. The Space Shuttle heritage hardware directly reused on SLS includes the Orbiter TVC hydraulic servo-actuators (with two slight design modifications), the Orbiter hydraulic circulation pumps, the Orbiter gimbal block/bearing, and the Solid Rocket Booster hydraulic pumps. The Core Auxiliary Power Unit (CAPU) is derived from the Orbiter Auxiliary Power Unit (APU). The Orbiter and Solid Rocket Booster APU turbines are powered by hot gas produced by catalyzed hydrazine decomposition. On the SLS Core Stage, the CAPU turbine is spun using cold gas tapped-off from the RS-25 to CS liquid hydrogen autogenous pressurization line. While direct reuse or slight modification of existing hardware may seem to be a triple-win for a program in cost, schedule, and technical risk mitigation, those benefits can only be realized when its degree of application in a new system is carefully and thoughtfully managed. The heritage hardware reuse should be prescribed within the heritage design capability and reuse environments must lie within the envelope of heritage qualification testing. Despite the significant test and flight experience of the Shuttle heritage hardware components, successful integration with the newly designed CS TVC components and incorporation into the stage design proved to be a challenge which required re-qualification of the heritage hardware as well as thorough integrated testing to support flight certification. Examples of the challenges that were overcome include: re-qualifying heritage hardware to survive new shock and vibration environments, certifying performance of extensively modified heritage hardware, regenerating design insight due to lack of available heritage vendor data, showing compliance to modern structural design standards, translation of heritage requirements for analog avionics to modern digital avionics, and interfacing heritage mechanical hardware with newly designed avionics. This paper is the second installment in a seven-paper series surveying the design, engineering, test validation, and flight performance of the Core Stage Thrust Vector Control system. This paper will discuss several engineering challenges encountered during the development process for SLS CS TVC and how they were successfully overcome to reach flight readiness.
A torsional thrust stand, calibrated for impulse bits in the range of 0.1mNs -0.5 mNs, was used to measure impulse bits during two campaigns at the NASA/GRC VF-3 Vacuum test Facility. Metal Plasma Thrusters (MPTs) with targets of Molybdenum, Copper and Stainless Steel (as used in upper stages of launch vehicles that are abandoned in LEO) were tested. This paper describes data from Mo targets (called pucks). The Cu and ss data will be presented elsewhere. Model predictions (based on a simple circuit model and published plasma parameters) were validated by data from the calibrated torsional thrust stand. The Metal Plasma Thruster uses solid metal propellant, hence requires no liquids, gases, flow valves or flow controls and has no moving parts. Total impulse ~5000Ns/U provides orbit raising and drag compensation capability.
A torsional thrust stand, calibrated for impulse bits in the range of 0.1mNs -0.5 mNs, was used to measure impulse bits during two campaigns at the NASA/GRC VF-3 Vacuum test Facility. Metal Plasma Thrusters (MPTs) with targets of Molybdenum, Copper and Stainless Steel (as used in upper stages of launch vehicles that are abandoned in LEO) were tested. This paper describes data from Mo targets (called pucks). The Cu and ss data will be presented elsewhere. Model predictions (based on a simple circuit model and published plasma parameters) were validated by data from the calibrated torsional thrust stand. The Metal Plasma Thruster uses solid metal propellant, hence requires no liquids, gases, flow valves or flow controls and has no moving parts. Total impulse ~5000Ns/U provides orbit raising and drag compensation capability.
This presentation communicates an overview of a methodology developed by the National Aeronautics and Space Administration (NASA) Marshall Space Flight Center (MSFC) Thrust Vector Control (TVC) Systems Integration & Components Branch (MSFC-ER63). The methodology is based on NASA heritage TVC design practices and is designed to analyze the summation of static and quasi-static environments acting on a gimbaled rocket engine/motor system. The analysis determines the maximum overall expected induced torque acting on the rocket engine/motor system about the gimbal center of rotation and assumes a mathematical 3-Dimensional (3D) 2-Degree-of-Freedom (DOF) rigid-body pendulum model over a predefined range of angular motion. Additionally, it calculates the associated reaction force acting along a TVC actuator line-of-action (LOA) to maintain thrust vector holding operations. This methodology is particularly useful for determining maximum overall design loads for TVC actuator design-space shaping and requirements determination.
Thrust vector control (TVC) systems for rocket engine propulsion traditionally use a simple linear relationship to convert between actuator forces and torques about the engine gimbal’s center-of-rotation (COR). As shown in Equation (1), the torque about the gimbal COR is proportional to the applied actuator force and the TVC moment arm (MA)—the perpendicular distance between the TVC actuator’s line-of-action (LOA) and the engine gimbal’s COR. While this fundamental relationship remains valid and accurate in a two-dimensional (2D), one-degree-of-freedom (1-DOF) context—particularly in its non-linear formulation as described in the ER63 Technical Bulletin TB-02 (Derivation of Thrust Vector Control (TVC) Engine-Gimbal / Actuator Moment-Arm Geometry)—it becomes limited when extended to three-dimensional (3D), two-degree-of-freedom (2-DOF) analyses. In 3D, out-of-plane angular displacements can arise, causing the gimbaled engine plane-of-motion to become non-coplanar with the respective actuator plane-of-motion. Such misalignments occur due to the rod-end (RE) and/or tail-stock (TE) mounting geometry of individual TVC actuators. These geometric complexities lead to inaccuracies in calculating engine torques and corresponding actuator forces if only the traditional TVC MA relationship is employed. For higher gimbal angular displacements (e.g., greater than 5 degrees), these inaccuracies become more pronounced, necessitating a more robust mathematical framework. This document presents a comprehensive 3D (2-DOF) derivation of a transformation matrix that accurately converts between gimbaled engine torques and TVC actuator forces. By incorporating the necessary geometric and rotational considerations, this new approach corrects the limitations of the traditional TVC MA method. Subsequent sections compare the newly formulated approach to the traditional method, demonstrating its enhanced accuracy and reliability for a broad range of gimbaled engine conditions.
Results are presented by which a high thrust reaction control system (RCS) can be used to complete insertion of the Gateway into a Near Rectilinear Halo Orbit (NRHO) in the event of a missed thrust event (MTE).Recovery solutions are presented in terms of the response time afforded, the ∆v required, and the NRHO insertion delay relative to the reference trajectory. Results are presented for methodologies that maintain the reference trajectory NRHO insertion epoch as well as those that optimize this insertion epoch in order to buy down recovery costs and increase the robustness of solutions. This analysis presents solutions which, in the event of an MTE during NRHO insertion, enable RCS recoveries that require under 20 m/s ∆v and less than four days of NRHO insertion delay.
A performance model is presented for magnetic nozzle plasmas driven by electron thermal expansion to investigate how the thrust coefficient and beam divergence efficiency scale with the incoming plasma flow and magnetic field geometry. Using a transformation from cylindrical to magnetic coordinates, an approximate analytical solution is derived to the axisymmetric two-fluid equations for a collisionless plasma flow along an applied magnetic field. This solution yields an expression for the half-width at half-maximum of the plasma density profile in the far-downstream region, from which simple scaling relations for the thrust coefficient and beam divergence efficiency are derived. It is found that the beam divergence efficiency is most sensitive to the density profile of the flow into the nozzle throat, with the highest efficiencies occurring for plasmas concentrated along the nozzle axis. Increasing the expansion ratio of the magnetic field leads to efficiency improvements that are more pronounced for incoming plasmas that are not concentrated along the axis. This implies that the additional magnet required to increase the expansion ratio may be worth the added complexity for plasma sources that exhibit poor confinement.
The Kernel Thrust milestone ADSE22-214 covers the development of device-capable optimization algorithms and solvers technologies required by the ExaSGD project’s software stack in order to solve security-constrained alternating current optimal power flow (SC-ACOPF) problems on emerging exascale architectures. To this extent, in FY21 the main objective of the Kernel Thrust was (i) provide robust optimization solver(s) that run efficiently on hardware accelerator devices (i.e., NVIDIA and AMD GPUs) to perform intra-node computations and (ii) provide coarse-grain parallel optimization capabilities that exploit the decomposition opportunities present in the SC-ACOPF challenge problems to provide exascale-capable solvers.
Experimentally measuring the pressure gain through the method of equivalent available pressure is prone to many experimental uncertainties. This study performs a detailed uncertainty analysis of the thrust and pressure gain measurements utilizing data from a H2/air operated rotating detonation combustor with an axial air inlet and a 50% exit constriction. The measured (negative) pressure gain values agree with the results in literature for similar inlet-to-exit area ratios. Specific considerations are given to the uncertainty in thrust measurement introduced by the base drag correction on the inner-body. The assumed unity Mach number utilized in the equivalent available pressure methodology is evaluated experimentally with two different methods using time-averaged measurements at the exhaust plane. A definitive demonstration of gain will be challenging given the assessed uncertainties, but recommendations are given to increase the precision of the equivalent available pressure methodology to estimate pressure gain.
The three dimensional optimum trajectory relations developed by Messrs J. G. Cox and W. A. Shaw in Reference I, are transformed into- a form that appears more amenable to low thrust trajectory calculations. Orbital element coordinates, commonly used in Celestial Mechanics, are employed due to their slow variation in low thrust applications. Combinations of these elements and a generalized eccentric anomaly are utilized in arranging the resulting equations- in a form which does not contain circular singularities.
Computer program for optimization of low thrust interplanetary trajectories assuming constant and continuous thrust from given initial and final position, velocity and flight time
Engine thrust vectoring and thrust modulation for control of V/STOL aircraft during hover
Combined electric constant low thrust and chemical or nuclear high thrust space propulsion systems for interplanetary missions
Low thrust trajectories for minimum time rendezvous between continuous thrust interceptor and passive target vehicle, comparing calculus of variations and steepest ascent analyses
Ablative materials in hydrogen/oxygen thrust chamber using expansion nozzle to substitute regenerative thrust chamber assembly