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All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Design of a Thrust Vector Servoelastic Filter for SLS Block 2 Booster Thrust Vector Control System

This paper presents a method to improve the thrust vector servoelastic (TVSE) response of a launch vehicle. TVSE is the coupling between the Thrust Vector Control (TVC) system nozzle dynamics and the vehicle flexible modes. A poorly phased TVC response, i.e. in phase with the structural velocity, can lead to instability of the flexible modes due to the energy injection from the thrust. For large boosters with heavy nozzles, TVSE is more likely to cause instability. This instability is part of the plant dynamics and may not be readily detected by the flight control system. In this paper, TVSE is treated as a disturbance rejection problem with the inertial force of the flexible motion viewed as an external disturbance to the TVC actuator control system. By effectively rejecting this disturbance, the engine can be decoupled from the flexible dynamics thus improving TVSE stability. The actuator disturbance transfer function is modified by inserting a filter into the servo-loop control system. The filter aims to reduce the magnitude and introduce phase lead of the disturbance transfer function over the TVSE sensitive frequency range while maintaining adequate stability margins of the actuator control system. A prefilter is also designed to improve command tracking performance. The filter and prefilter resulting from this method are usually of low order and can be included to an existing actuator controller if the controller is programmable. This method was demonstrated for a hydraulic Simplex actuator model. Its applications to the Space Launch System (SLS) Block 1 and Block 2 TVC actuator are also described. The Block 2 actuator controller was modified based on the results of this method. The tradeoff between TVSE stability and the servo-loop stability can be balanced by adjusting the amount of phase lead introduced by the TVSE filter. This method provides a useful way to solve the TVSE instability issue without costly and time-consuming hardware solutions. This method is based on the basic control principles of loop shaping and disturbance rejection and has been proven to be effective under proper circumstances.

Thrust vector control↗
NASA NTRS1992

Advanced electric motor technology: Flux mapping

This report contains the assumptions, mathematical models, design methodology, and design points involved with the design of an electromechanical actuator (EMA) suitable for directing the thrust vector of a large MSFC/NASA launch vehicle. Specifically the design of such an actuator for use on the upcoming liquid fueled National Launch System (NLS) is considered culminating in a point design of both the servo system and the electric motor needed. A major thrust of the work is in selecting spur gear and roller screw reduction ratios to achieve simultaneously wide bandwidth, maximum power transfer, and disturbance rejection while meeting specified horsepower requirements at a given stroking speed as well as a specified maximum stall force. An innovative feedback signal is utilized in meeting these diverse objectives.

Doane, George B., III↗
NASA NTRS1994

Computational prediction of isolated performance of an axisymmetric nozzle at Mach number 0.90

An improved ability to predict external propulsive performance was incorporated into the three-dimensional Navier-Stokes code PAB3D. The improvements are the ability to account for skin friction and external pressure forces. Performance parameters for two axisymmetric supersonic cruise nozzle configurations were calculated to test the improved methodology. Internal and external flow-field regions were computed using a two-equation kappa-epsilon turbulent viscous-stress model. The computed thrust-minus-drag ratios were within 1 percent of the absolute level of experimental data and the trends of data were predicted accurately. The predicted trend of integrated nozzle pressure drag matched the trend of the integrated experimental pressure drag over a range of nozzle pressure ratios, but absolute drag levels were not accurately predicted.

Carlson, John R.↗
NASA NTRS1946

Altitude-Wind-Tunnel Investigation of Performance of Several Propellers on YP-47M Airplane at High Blade Loadings: Hamilton Standard 6507A-2 Four- and Three-Blade Propellers - 6

An altitude-wind-tunnel investigation has been made to determine the performance of Hamilton Standard 6507A-2 four-blade and three-blade propellers on a YP-47M airplane at high blade loadings and high engine powers. Characteristics of the four-blase propeller were obtained for a range of power coefficients from 0.10 to 1.00 at free-stream Mach numbers of 0.20, 0.30, 0.40. Characteristics of the three-blade propeller were obtained for a range of power coefficients from 0.30 to 1.00 at a free-stream Mach number of 0.40. Results of the force measurements indicate primarily the trend of propeller efficiency for changes in power coefficient or advance-diameter ratio because no corrections for the effects of tunnel-wall constriction on the installation were applied. Slipstream surveys are presented to illustrate blade thrust load distribution for certain operating conditions. Within the range of advance-diameter ratios investigated at each free-stream Mach number, the efficiency of the four-blade propeller decreased as the power coefficient was increased from 0.10 to 1.00. For the three-blade propeller, nearly constant maximum efficiencies were obtained for power coefficients from 0.32 to 0.63 at advance-diameter ratios between 1.90 and 3.00. In general, for conditions below the stall and critical tip Mach number, the maximum thrust load shifted from the inboard sections toward the tip sections as the power coefficient was increased or as the advance-diameter ratio was decreased. For conditions beyond the stall or critical tip Mach number, losses in thrust occurred on the outboard blade sections owing to flow break-down; the thrust load increased slightly on the inboard sections.

Saari, Martin J.↗
NASA NTRS2007

Optimal Electrodynamic Tether Phasing Maneuvers

We study the minimum-time orbit phasing maneuver problem for a constant-current electrodynamic tether (EDT). The EDT is assumed to be a point mass and the electromagnetic forces acting on the tether are always perpendicular to the local magnetic field. After deriving and non-dimensionalizing the equations of motion, the only input parameters become current and the phase angle. Solution examples, including initial Lagrange costates, time of flight, thrust plots, and thrust angle profiles, are given for a wide range of current magnitudes and phase angles. The two-dimensional cases presented use a non-tilted magnetic dipole model, and the solutions are compared to existing literature. We are able to compare similar trajectories for a constant thrust phasing maneuver and we find that the time of flight is longer for the constant thrust case with similar initial thrust values and phase angles. Full three-dimensional solutions, which use a titled magnetic dipole model, are also analyzed for orbits with small inclinations.

Bitzer, Matthew S.↗
NASA NTRS2016

Hot-Fire Test Results of Liquid Oxygen/RP-2 Multi-Element Oxidizer-Rich Preburners

As part of the Combustion Stability Tool Development project funded by the Air Force Space and Missile Systems Center, the NASA Marshall Space Flight Center was contracted to assemble and hot-fire test a multi-element integrated test article demonstrating combustion characteristics of an oxygen/hydrocarbon propellant oxidizer-rich staged-combustion engine thrust chamber. Such a test article simulates flow through the main injectors of oxygen/kerosene oxidizer-rich staged combustion engines such as the Russian RD-180 or NK-33 engines, or future U.S.-built engine systems such as the Aerojet-Rocketdyne AR-1 engine or the Hydrocarbon Boost program demonstration engine. To supply the oxidizer-rich combustion products to the main injector of the integrated test article, existing subscale preburner injectors from a previous NASA-funded oxidizer-rich staged combustion engine development program were utilized. For the integrated test article, existing and newly designed and fabricated inter-connecting hot gas duct hardware were used to supply the oxidizer-rich combustion products to the oxidizer circuit of the main injector of the thrust chamber. However, before one of the preburners was used in the integrated test article, it was first hot-fire tested at length to prove it could provide the hot exhaust gas mean temperature, thermal uniformity and combustion stability necessary to perform in the integrated test article experiment. This paper presents results from hot-fire testing of several preburner injectors in a representative combustion chamber with a sonic throat. Hydraulic, combustion performance, exhaust gas thermal uniformity, and combustion stability data are presented. Results from combustion stability modeling of these test results are described in a companion paper at this JANNAF conference, while hot-fire test results of the preburner injector in the integrated test article are described in another companion paper.

Protz, C. S.↗
NASA NTRS2016

Hot-Fire Test Results of an Oxygen/RP-2 Multi-Element Oxidizer-Rich Staged-Combustion Integrated Test Article

As part of the Combustion Stability Tool Development project funded by the Air Force Space and Missile Systems Center, the NASA Marshall Space Flight Center was contracted to assemble and hot-fire test a multi-element integrated test article demonstrating combustion characteristics of an oxygen/hydrocarbon propellant oxidizer-rich staged-combustion engine thrust chamber. Such a test article simulates flow through the main injectors of oxygen/kerosene oxidizer-rich staged combustion engines such as the Russian RD-180 or NK-33 engines, or future U.S.-built engine systems such as the Aerojet-Rocketdyne AR-1 engine or the Hydrocarbon Boost program demonstration engine. For the thrust chamber assembly of the test article, several configurations of new main injectors, using relatively conventional gas-centered swirl coaxial injector elements, were designed and fabricated. The design and fabrication of these main injectors are described in a companion paper at this JANNAF meeting. New ablative combustion chambers were fabricated based on hardware previously used at NASA for testing at similar size and pressure. An existing oxygen/RP-1 oxidizer-rich subscale preburner injector from a previous NASA-funded program, along with existing and new inter-connecting hot gas duct hardware, were used to supply the oxidizer-rich combustion products to the oxidizer circuit of the main injector of the thrust chamber. Results from independent hot-fire tests of the preburner injector in a combustion chamber with a sonic throat are described in companion papers at this JANNAF conference. The resulting integrated test article - which includes the preburner, inter-connecting hot gas duct, main injector, and ablative combustion chamber - was assembled at Test Stand 116 at the East Test Area of the NASA Marshall Space Flight Center. The test article was well instrumented with static and dynamic pressure, temperature, and acceleration sensors to allow the collected data to be used for combustion analysis model development. Hot-fire testing was conducted with main combustion chamber pressures ranging from 1400 to 2100 psia, and main combustion chamber mixture ratios ranging from 2.4 to 2.9. Different levels of fuel film cooling injected from the injector face were examined ranging from none to about 12% of the total fuel flow. This paper presents the hot-fire test results of the integrated test article. Combustion performance, stability, thermal, and compatibility characteristics of both the preburner and the thrust chamber are described. Another companion paper at this JANNAF meeting includes additional and more detailed test data regarding the combustion dynamics and stability characteristics.

Hulka, J. R.↗
NASA NTRSDate not supplied

Application of OpenFOAM to Plume Impingement in Space Environments

After 30 years of continuous human presence in low-earth orbit, NASA is returning to the moon and eventually will go to Mars. Travelling beyond low earth orbit requires NASA to learn how humans can live in Deep Space environments – beyond the protection of Earth’s magnetosphere and at distances from Earth that prevent a quick return in case of trouble. To this end, NASA is constructing the Lunar Gateway, an ISS-like space station to be put in orbit around the moon to act as a home base for Lunar exploration for NASA astronauts. The Gateway Lunar outpost will be built incrementally, via modules which will arrive at separate times and dock to the existing structure. The incremental addition of Gateway modules, and the docking of visiting vehicles, is achieved via a sequence of firings from the approaching body’s onboard reaction control system (RCS) thrusters to achieve the required approach trajectory. The typical hypergolic chemical RCS thrusters work by firing hot gases to produce adverse thrust and the needed change in velocity to safely finish the docking process. The exhaust gas from the RCS thrusters form plumes that expand into the vacuum of space and can impinge onto the outer surfaces of the Lunar Gateway, causing unwanted forces and moments, heat loads, sediment deposition, and in extreme cases, even surface erosion - all mechanisms that can damage the Lunar Gateway and must be minimized. Both permanent and visiting modules will have this RCS thruster exhaust impingement problem. This research aims to establish existing OpenFOAM solvers as a methodology for improving simulation techniques of rocket exhaust plume impingement in space environments. The flow structure of a plume in a space environment is complex; a plume that originates from a hypergolic chemical RCS thruster and expands into a vacuum will experience several regimes of rarefication. This range includes the continuum flow in the rocket nozzle through the fully rarefied free molecular flow further from the nozzle. The flow physics is different at these two extremes, and as such, the simulation approach for plumes is generally divided into a traditional computational fluid dynamics (CFD) simulation in and near the nozzle which is coupled to a subsequent direct simulation Monte Carlo (DSMC) simulation. At this time, the scope of this research is developing, verifying, and validating a method using existing solvers in the OpenFOAM framework for performing coupled CFD/DSMC calculations to determine the extent of plume impingement loading on generic space structures. This presentation will detail code-to-code comparisons between the hyStrath dsmcFoam+ solver, developed using OpenFOAM and available as open-source, and NASA’s in-house DSMC Analysis Code (DAC). Comparisons to several open-source publication findings using DAC [3,4] are presented, and advantages of using an OpenFOAM based solver are also discussed. The presentation concludes with a discussion of future work, and a plan for coupling the dsmcFoam+ solver with CFD simulations of chemical rocket engines for unified coupled plume simulation.

DSMC↗
NASA NTRS2015

Numerical Computation of a Continuous-thrust State Transition Matrix Incorporating Accurate Hardware and Ephemeris Models

A significant body of work exists showing that providing a nonlinear programming (NLP) solver with expressions for the problem constraint gradient substantially increases the speed of program execution and can also improve the robustness of convergence, especially for local optimizers. Calculation of these derivatives is often accomplished through the computation of spacecraft's state transition matrix (STM). If the two-body gravitational model is employed as is often done in the context of preliminary design, closed form expressions for these derivatives may be provided. If a high fidelity dynamics model, that might include perturbing forces such as the gravitational effect from multiple third bodies and solar radiation pressure is used then these STM's must be computed numerically. We present a method for the power hardward model and a full ephemeris model. An adaptive-step embedded eight order Dormand-Prince numerical integrator is discussed and a method for the computation of the time of flight derivatives in this framework is presented. The use of these numerically calculated derivatieves offer a substantial improvement over finite differencing in the context of a global optimizer. Specifically the inclusion of these STM's into the low thrust missiondesign tool chain in use at NASA Goddard Spaceflight Center allows for an increased preliminary mission design cadence.

Low Thrust↗
NASA NTRS1973

RCS jet-flow field interaction effects on the aerodynamics of the space shuttle orbiter

A study was conducted to determine the external effects caused by operation of the reaction control system during entry of the space shuttle orbiter. The effects of jet plume-external flow interactions were emphasized. Force data were obtained for the basic airframe characteristics plus induced effects when the reaction control system is operating. Resulting control amplification and/or coupling were derived and their effects on the aerodynamic stability and control of the orbiter and the reaction control system thrust were determined.

Rausch, J. R.↗
NASA NTRS1983

Interference effects of aft reaction-control yaw jets on the aerodynamic characteristics of a space shuttle orbiter model at supersonic speeds

A wind tunnel investigation of the interference effects of aft reaction control system yaw jet plumes on a 0.0125 scale Space Shuttle orbiter model was conducted at Mach numbers from 2.50 to 4.50. Test variables included model angle of attack, model angle of sideslip, jet to free stream mass flow ratio, and number and position of operating jets. The aft reaction control jet plume creates a blockage above and behind the wing on the side in which the jet exhausts and results in flow separation on the wing upper surface and fuselage side. Positive pitching moment and side force increments and negative yawing moment and rolling moment increments due to the flow separations are incurred for left side firing jets, primarily at angles of attack above 10 deg. The yawing moment interference increments are favorable and result in a small jet thrust amplification. As a result of this investigation, the aft reaction control system was certified for operation at supersonic Mach numbers prior to the first flight of the space transportation system (STS-1).

Covell, P. F.↗
NASA NTRS1982

Magnetoplasmadynamic thruster development

Current research on self-field MPD thrusters presents the possibility of developing high power/low cost electric propulsion. The interest generated in this propulsion concept within both NASA and the U.S. Air Force has led to a coordinated interagency effort, and the recent completion of several test sites are expected to speed thruster concept development. Efficiencies approaching 40% at 2200 sec have been experimentally demonstrated. Among the characteristics recommending development of MPD thrusters are high thrust density and power handling capability, simplicity, and a wide dynamic range of thrust and specific impulse. MPD thrusters can, moreover, operate either continuously, at high available power levels, or in a pulsed mode, to match lower power levels.

Pawlik, E. V.↗
NASA NTRS1983

Combustion performance and heat transfer characterization of LOX/hydrocarbon type propellants

An evaluation liquid oxygen (LOX) and various hydrocarbon fuels as low cost alternative propellants suitable for future space transportation system applications was done. The emphasis was directed toward low earth orbit maneuvering engine and reaction control engine systems. The feasibility of regeneratively cooling an orbit maneuvering thruster was analytically determined over a range of operating conditions from 100 to 1000 psia chamber pressure and 1000 to 10,000-1bF thrust, and specific design points were analyzed in detail for propane, methane, RP-1, ammonia, and ethanol; similar design point studies were performed for a film-cooled reaction control thruster. Heat transfer characteristics of propane were experimentally evaluated in heated tube tests. Forced convection heat transfer coefficients were determined. Seventy-seven hot firing tests were conducted with LOX/propane and LOX/ethanol, for a total duration of nearly 1400 seconds, using both heat sink and water-cooled calorimetric chambers. Combustion performance and stability and gas-side heat transfer characteristics were evaluated.

Michel, R. W.↗
NASA NTRS2002

Spiral Orbit Tribometry I: Description of the Tribometer

A new rolling contact tribometer based on a planar thrust bearing geometry is described. The bearing 'races' are flat plates that drive a ball into a near-circular, spiral path. The spiraling ball is returned to its initial radius each revolution around the race by a 'guide plate' backed by a force transducer. The motions of the ball are analyzed and the force exerted by the ball on the guide plate is related to the friction coefficient of the system. The experimental characteristics of the system are presented and the system is shown to exhibit the behavior expected for a tribometer.

Pepper, Stephen V.↗
NASA NTRS2004

Rotor Airloads Prediction Using Loose Aerodynamic Structural Coupling

This work couples a computational fluid dynamics (CFD) code and rotorcraft computational structural dynamics (CSD) code to calculate helicopter rotor airloads across a range of flight conditions. An iterative loose (weak) coupling methodology is used to couple the CFD and CSD codes on a per revolution, periodic basis. The CFD uses a high fidelity, Navier-Stokes, overset grid methodology with first principles-based wake capturing. Modifications are made to the CFD code for aeroelastic analysis. For a UH-60A Blackhawk helicopter, four challenging level flight conditions are computed: 1) low speed (u = 0.15) with blade-vortex interaction, 2) high speed (u = 0.37) with advancing blade negative lift, 3) high thrust with dynamic stall (u = 0.24), and 4) hover. Results are compared with UH-60A Airloads Program fight test data. Most importantly, for all cases the loose coupling methodology is shown to be stable, convergent, and robust with full coupling of normal force, pitching moment, and chord force. In comparison with flight test data, normal force and pitching moment magnitudes are in good agreement. For the high speed and dynamic stall cases a phase lag in comparison with the data is seen, nonetheless, the shapes of the curves are very good. Overall, the results are noteworthy improvement over lifting line aerodynamics used in rotorcraft comprehensive codes.

Potsdam, Mark↗
NASA NTRS1973

Advanced space engine preliminary design

Analysis and design of an optimum LO2/LH2, combustion topping cycle, 88,964 Newtons (20,000-pound) thrust, liquid rocket engine was conducted. The design selected is well suited to high-energy, upper-stage engine applications such as the Space Tug and embodies features directed toward optimization of vehicle performance. A configuration selection was conducted based on prior Air Force Contracts, and additional criteria for optimum stage performance. Following configuration selection, analyses and design of the major components and engine systems were conducted to sufficient depth to provide layout drawings suitable for subsequent detailing. In addition, engine packaging to a common interface and a retractable nozzle concept were defined. Alternative development plans and related costs were also established. The design embodies high-performance, low-weight, low NPSH requirements (saturated propellant inlet conditions at start), idle-mode operation, and autogenous pressurization. The design is the result of the significant past and current LO2/LH2 technology efforts of the NASA centers and the Air Force, as well as company-funded programs.

Zachary, A. T.↗
NASA NTRS2004

"Fan-Tip-Drive" High-Power-Density, Permanent Magnet Electric Motor and Test Rig Designed for a Nonpolluting Aircraft Propulsion Program

A scaled blade-tip-drive test rig was designed at the NASA Glenn Research Center. The rig is a scaled version of a direct-current brushless motor that would be located in the shroud of a thrust fan. This geometry is very attractive since the allowable speed of the armature is approximately the speed of the blade tips (Mach 1 or 1100 ft/s). The magnetic pressure generated in the motor acts over a large area and, thus, produces a large force or torque. This large force multiplied by the large velocity results in a high-power-density motor.

Brown, Gerald V.↗
NASA NTRS2005

Spacecraft Solar Sails Containing Electrodynamic Tethers

A report discusses a proposal to use large, lightweight solar sails embedded with electrodynamic tethers (essentially, networks of wires) to (1) propel robotic spacecraft to distant planets, then (2) exploit the planetary magnetic fields to capture the spacecraft into orbits around the planets. The purpose of the proposal is, of course, to make it possible to undertake long interplanetary missions without incurring the large cost and weight penalties of conventional rocket-type propulsion systems. Through transfer of momentum from reflected solar photons, a sail would generate thrust outward from the Sun. Upon arrival in the vicinity of a planet, the electrodynamic tethers would be put to use: Motion of the spacecraft across the planetary magnetic field would induce electric currents in the tether wires, giving rise to an electromagnetic drag force that would be exploited to brake the spacecraft for capture into orbit. The sail with embedded tethers would be made to spin to provide stability during capture. Depending upon the requirements of a particular application, it could be necessary to extend the tether to a diameter greater than that of the sail.

Johnson, Les↗