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NASA NTRS1964

Vehicle Walks on Varied Terrain, Can Assist Handicapped Persons

The problem: Designing a vehicle capable of traversing varied terrain at moderate speeds (up to 4 miles per hour). Development of such a vehicle was originally undertaken to meet NASA requirements for a remotely controlled instrument carrier to be used for unmanned exploration of lunar and planetary surfaces. The solution: A battery-powered motorized vehicle with three pairs of legs that are connected to push rods and a series of linkages. How it's done: Locomotion of the basic vehicle is accomplished by three pairs of legs, one pair in the front and two pairs in the rear. Each leg consists of an upper horizontal portion, a middle vertical portion, and a foot. Two cams connected to the drive mechanism (a small motor, gearbox, and push rods) control the motion of the legs. The two outer rear legs move in unison with the right front leg, and the two inner rear legs move in unison with the left front leg. Each set of three legs is lifted to clear or rest on any expected obstacle on the terrain to be traversed by the vehicle and advanced a fixed distance for the succeeding step. A system of spring-loaded vertical-motion linkages permits obstacles (within design limitations) to be traversed with a minimum disturbance of the vehicle's axes. The linkages are arranged to permit the legs to be folded when the vehicle is stored. Steering is accomplished by a small motor, which swings the front pair of legs to the desired angle. The rear legs are connected by a differential linkage to compensate for the required variation in step length or speed between the right and left pairs of rear legs when turns are made.

Source record↗

NASA NTRS2000

X-38 Vehicle 131R Free Flights 1 and 2

The X-38 program is using a modern flight control system (FCS) architecture originally developed by Honeywell called MACH. During last year's SAE G&C subcommittee meeting, we outlined the design, implementation and testing of MACH in X-38 Vehicles 132, 131R & 201. During this year's SAE meeting, I'll focus upon the first two free flights of V131R, describing what caused the roll-over in FF1 and how we fixed it for FF2. I only have 30 minutes, so it will be a quick summary including VHS video. X-38 is a NASA JSC/DFRC experimental flight test program developing a series of prototypes for an International Space Station (ISS) Crew Return Vehicle (CRV), often described as an ISS "lifeboat." X-38 Vehicle 132 Free Flight 3 was the first flight test of a modern FCS architecture called Multi-Application ControlH (MACH), developed by the Honeywell Technology Center in Minneapolis and Honeywell's Houston Engineering Center. MACH wraps classical Proportional+integral (P+I) outer attitude loops around modern dynamic inversion attitude rate loops. The presentation at last year's SAE Aerospace Meeting No. 85 focused upon the design and testing of the FCS algorithm and Vehicle 132 Free Flight 3. This presentation will summarize flight control and aerodynamics lessons learned during Free Flights 1 and 2 of Vehicle 131R, a subsonic test vehicle laying the groundwork for the orbital/entry test of Vehicle 201 in 2003.

Munday, Steve↗

NASA NTRS2006

NASA Crew Launch Vehicle Approach Builds on Lessons from Past and Present Missions

The United States Vision for Space Exploration, announced in January 2004, outlines the National Aeronautics and Space Administration's (NASA) strategic goals and objectives, including retiring the Space Shuttle and replacing it with a new human-rated system suitable for missions to the Moon and Mars. The Crew Exploration Vehicle (CEV) that the new Crew Launch Vehicle (CLV) lofts into space early next decade will initially ferry astronauts to the International Space Station and be capable of carrying crews back to lunar orbit and of supporting missions to Mars orbit. NASA is using its extensive experience gained from past and ongoing launch vehicle programs to maximize the CLV system design approach, with the objective of reducing total lifecycle costs through operational efficiencies. To provide in-depth data for selecting this follow-on launch vehicle, the Exploration Systems Architecture Study was conducted during the summer of 2005, following the confirmation of the new NASA Administrator. A team of aerospace subject matter experts used technical, budget, and schedule objectives to analyze a number of potential launch systems, with a focus on human rating for exploration missions. The results showed that a variant of the Space Shuttle, utilizing the reusable Solid Rocket Booster as the first stage, along with a new upper stage that uses a derivative of the RS-25 Space Shuttle Main Engine to deliver 25 metric tons to low-Earth orbit, was the best choice to reduce the risks associated with fielding a new system in a timely manner. The CLV Project, managed by the Exploration Launch Office located at NASA's Marshall Space Flight Center, is leading the design, development, testing, and operation of this new human-rated system. The CLV Project works closely with the Space Shuttle Program to transition hardware, infrastructure, and workforce assets to the new launch system . leveraging a wealth of lessons learned from Shuttle operations. The CL V is being designed to reduce costs through a number of methods, ranging from validating requirements to conducting trades studies against the concept design. Innovations such as automated processing will build on lessons learned from the Shuttle, other launch systems, Department of Defense operations experience, and subscale flight tests such as the Delta Clipper-Experimental Advanced (DCXA) vehicle operations that utilized minimal touch labor, automated cryogen ic propellant loading , and an 8-hour turnaround for a cryogenic propulsion system. For the CLV, the results of hazard analyses are contributing to an integrated vehicle health monitoring system that will troubleshoot anomalies and determine which ones can be solved without human intervention. Such advances will help streamline the mission operations process for pilots and ground controllers alike. In fiscal year 2005, NASA invested approximately $4.5 billion of its $16 bill ion budget on the Space Shuttle. The ultimate goal of the CLV Project is to deliver a safe, reliable system designed to minimize lifecycle costs so that NASA's budget can be invested in missions of scientific discovery. Lessons learned from developing the CLV will be applied to the growth path for future systems, including a heavy lift launch vehicle.

Dumbacher, Daniel L.↗

NASA NTRS2012

Current CFD Practices in Launch Vehicle Applications

The quest for sustained space exploration will require the development of advanced launch vehicles, and efficient and reliable operating systems. Development of launch vehicles via test-fail-fix approach is very expensive and time consuming. For decision making, modeling and simulation (M&S) has played increasingly important roles in many aspects of launch vehicle development. It is therefore essential to develop and maintain most advanced M&S capability. More specifically computational fluid dynamics (CFD) has been providing critical data for developing launch vehicles complementing expensive testing. During the past three decades CFD capability has increased remarkably along with advances in computer hardware and computing technology. However, most of the fundamental CFD capability in launch vehicle applications is derived from the past advances. Specific gaps in the solution procedures are being filled primarily through "piggy backed" efforts.on various projects while solving today's problems. Therefore, some of the advanced capabilities are not readily available for various new tasks, and mission-support problems are often analyzed using ad hoc approaches. The current report is intended to present our view on state-of-the-art (SOA) in CFD and its shortcomings in support of space transport vehicle development. Best practices in solving current issues will be discussed using examples from ascending launch vehicles. Some of the pacing will be discussed in conjunction with these examples.

Kwak, Dochan↗

NASA NTRS2012

Application of System Operational Effectiveness Methodology to Space Launch Vehicle Development and Operations

The Department of Defense (DoD) defined System Operational Effectiveness (SOE) model provides an exceptional framework for an affordable approach to the development and operation of space launch vehicles and their supporting infrastructure. The SOE model provides a focal point from which to direct and measure technical effectiveness and process efficiencies of space launch vehicles. The application of the SOE model to a space launch vehicle's development and operation effort leads to very specific approaches and measures that require consideration during the design phase. This paper provides a mapping of the SOE model to the development of space launch vehicles for human exploration by addressing the SOE model key points of measurement including System Performance, System Availability, Technical Effectiveness, Process Efficiency, System Effectiveness, Life Cycle Cost, and Affordable Operational Effectiveness. In addition, the application of the SOE model to the launch vehicle development process is defined providing the unique aspects of space launch vehicle production and operations in lieu of the traditional broader SOE context that examines large quantities of fielded systems. The tailoring and application of the SOE model to space launch vehicles provides some key insights into the operational design drivers, capability phasing, and operational support systems.

Watson, Michael D.↗

NASA NTRS2013

Ceramic Adhesive and Methods for On-Orbit Repair of Re-Entry Vehicles

This adhesive is capable of repairing damaged leading edge components of reentry vehicles while in space, and is novel with regard to its ability to be applied in the vacuum of space, and in a microgravity environment. Once applied, the adhesive provides thermal and oxidation protection to the substrate (in this case, reinforced carbon/carbon composites, RCCs) during re-entry of a space vehicle. Although there may be many formulations for repair adhesives, at the time of this reporting, this is the first known adhesive capable of an on-orbit repair. The adhesive is an engineered ceramic material composed of a pre-ceramic polymer and refractory powders in the form of a paste or putty that can be applied to a scratched, cracked, or fractured composite surface, covering and protecting the damaged area. The adhesive is then "cured" with a heat cycle, thereby cross-linking the polymer into a hardened material and bonding it to the substrate. During the heat of reentry, the material is converted to a ceramic coating that provides thermal and oxidative stability to the repaired area, thus allowing the vehicle to pass safely from space into the upper atmosphere. Ceramic powders such as SiC, ZrB2 and Y2O3 are combined with allylhydridopolycarbosilane (AHPCS) resin, and are mixed to form a paste adhesive. The material is then applied to the damaged area by brush, spatula, trowel, or other means to fill cracks, gaps, and holes, or used to bond patches onto the damaged area. The material is then cured, in a vacuum, preferably at 250F (approximately equal to 121C) for two hours. The re-entry heating of the vehicle at temperatures in excess of 3,000F (approximately equal to 1,650C) then converts this material into a ceramic coating. This invention has demonstrated advantages in resistance to high temperatures, as was demonstrated in more than 100 arc-jet tests in representative environments at NASA. Extensive testing verified oxidation protection for the repaired substrate (RCC), and confirmed that the microstructure of the resulting repair leads to durability and resistance to melting or flow. Its processability and working life in a vacuum was demonstrated by NASA astronauts in glovebox processing studies, as well as on-orbit in the open space shuttle bay. All of these advantages increase the working life of NASA vehicles, as well as improve safety for any crew on a manned vehicle. The adhesive, trademarked NOAX(TM). or Non-Oxide Adhesive Experimental, flew on all space shuttle missions from Return To Flight (STS-114) until the final flight (STS- 135) as a crack repair material for the leading edges and nose cap of the vehicle. NOAX(TM) was patented under U.S. Patents 7,628,878 and 7,888,277.

Riedell, James A.↗

NASA NTRS2013

Small Launch Vehicle Trade Space Definition: Development of a Zero Level Mass Estimation Tool with Trajectory Validation

Recent high level interest in the capability of small launch vehicles has placed significant demand on determining the trade space these vehicles occupy. This has led to the development of a zero level analysis tool that can quickly determine the minimum expected vehicle gross liftoff weight (GLOW) in terms of vehicle stage specific impulse (Isp) and propellant mass fraction (pmf) for any given payload value. Utilizing an extensive background in Earth to orbit trajectory experience a total necessary delta v the vehicle must achieve can be estimated including relevant loss terms. This foresight into expected losses allows for more specific assumptions relating to the initial estimates of thrust to weight values for each stage. This tool was further validated against a trajectory model, in this case the Program to Optimize Simulated Trajectories (POST), to determine if the initial sizing delta v was adequate to meet payload expectations. Presented here is a description of how the tool is setup and the approach the analyst must take when using the tool. Also, expected outputs which are dependent on the type of small launch vehicle being sized will be displayed. The method of validation will be discussed as well as where the sizing tool fits into the vehicle design process.

Waters, Eric D.↗

NASA NTRS2015

Assimilation of Wind Profiles from Multiple Doppler Radar Wind Profilers for Space Launch Vehicle Applications

Atmospheric wind data are required by space launch vehicles in order to assess flight vehicle loads and performance on day-of-launch. Space launch ranges at NASA's Kennedy Space Center co-located with the United States Air Force's (USAF) Eastern Range (ER) at Cape Canaveral Air Force Station and USAF's Western Range (WR) at Vandenberg Air Force Base have extensive networks of in-situ and remote sensing instrumentation to measure atmospheric winds. Each instrument's technique to measure winds has advantages and disadvantages in regards to use within vehicle trajectory analyses. Balloons measure wind at all altitudes necessary for vehicle assessments, but two primary disadvantages exist when applying balloon output. First, balloons require approximately one hour to reach required altitudes. Second, balloons are steered by atmospheric winds down range of the launch site that could significantly differ from those winds along the vehicle ascent trajectory. These issues are mitigated by use of vertically pointing Doppler Radar Wind Profilers (DRWPs). However, multiple DRWP instruments are required to provide wind data over altitude ranges necessary for vehicle trajectory assessments. The various DRWP systems have different operating configurations resulting in different temporal and spatial sampling intervals. Therefore, software was developed to combine data from both DRWP-generated profiles into a single profile for use in vehicle trajectory analyses. This paper will present details of the splicing software algorithms and will provide sample output.

Decker, Ryan K.↗

NASA NTRS2014

Co-Optimization of Blunt Body Shapes for Moving Vehicles

A method and associated system for multi-disciplinary optimization of various parameters associated with a space vehicle that experiences aerocapture and atmospheric entry in a specified atmosphere. In one embodiment, simultaneous maximization of a ratio of landed payload to vehicle atmospheric entry mass, maximization of fluid flow distance before flow separation from vehicle, and minimization of heat transfer to the vehicle are performed with respect to vehicle surface geometric parameters, and aerostructure and aerothermal vehicle response for the vehicle moving along a specified trajectory. A Pareto Optimal set of superior performance parameters is identified.

Brown, James L.↗

NASA NTRS2015

Payload Performance Analysis for a Reusable Two-Stage-to-Orbit Vehicle

This paper investigates a unique approach in the development of a reusable launch vehicle where, instead of designing the vehicle to be reusable from its inception, as was done for the Space Shuttle, an expendable two stage launch vehicle is evolved over time into a reusable launch vehicle. To accomplish this objective, each stage is made reusable by adding the systems necessary to perform functions such as thermal protection and landing, without significantly altering the primary subsystems and outer mold line of the original expendable vehicle. In addition, some of the propellant normally used for ascent is used instead for additional propulsive maneuvers after staging in order to return both stages to the launch site, keep loads within acceptable limits and perform a soft landing. This paper presents a performance analysis that was performed to investigate the feasibility of this approach by quantifying the reduction in payload capability of the original expendable launch vehicle after accounting for the mass additions, trajectory changes and increased propellant requirements necessary for reusability. Results show that it is feasible to return both stages to the launch site with a positive payload capability equal to approximately 50 percent of an equivalent expendable launch vehicle. Further discussion examines the ability to return a crew/cargo capsule to the launch site and presents technical challenges that would have to be overcome.

Tartabini, Paul V.↗

NASA NTRS2015

Comparison and Validation of FLUKA and HZETRN as Tools for Investigating the Secondary Neutron Production in Large Space Vehicles

NASA's exploration goals are focused on deep space travel and Mars surface operations. To accomplish these goals, large structures will be necessary to transport crew and logistics in the initial stages, and NASA will need to keep the crew and the vehicle safe during transport and any surface activities. One of the major challenges of deep space travel is the space radiation environment and its impacts on the crew, the electronics, and the vehicle materials. The primary radiation from the sun (solar particle events) and from outside the solar system (galactic cosmic rays) interact with materials of the vehicle. These interactions lead to some of the primary radiation being absorbed, being modified, or producing secondary radiation (primarily neutrons). With all vehicles, the high energy primary radiation is of most concern. However, with larger vehicles that have large shielding masses, there is more opportunity for secondary radiation production, and this secondary radiation can be significant enough to cause concern. When considering surface operations, there is also a secondary radiation source from the surface of the planet, known as albedo, with neutrons being one of the most significant species. Given new vehicle designs for deep space and Mars missions, the secondary radiation environment and the implications of that environment is currently not well understood. Thus, several studies are necessary to fill the knowledge gaps of this secondary radiation environment. In this paper, we put forth the initial steps to increasing our understanding of neutron production from large vehicles by comparing the neutron production resulting from our radiation transport codes and providing a preliminary validation of our results against flight data. This paper will review the details of these results and discuss the finer points of the analysis.

Rojdev, Kristina↗

NASA NTRS2016

Passive vs. Parachute System Architecture for Robotic Sample Return Vehicles

The Multi-Mission Earth Entry Vehicle (MMEEV) is a flexible vehicle concept based on the Mars Sample Return (MSR) EEV design which can be used in the preliminary sample return mission study phase to parametrically investigate any trade space of interest to determine the best entry vehicle design approach for that particular mission concept. In addition to the trade space dimensions often considered (e.g. entry conditions, payload size and mass, vehicle size, etc.), the MMEEV trade space considers whether it might be more beneficial for the vehicle to utilize a parachute system during descent/landing or to be fully passive (i.e. not use a parachute). In order to evaluate this trade space dimension, a simplified parachute system model has been developed based on inputs such as vehicle size/mass, payload size/mass and landing requirements. This model works in conjunction with analytical approximations of a mission trade space dataset provided by the MMEEV System Analysis for Planetary EDL (M-SAPE) tool to help quantify the differences between an active (with parachute) and a passive (no parachute) vehicle concept.

Maddock, Robert W.↗

NASA NTRS2014

Passive Thermal Control for the Low Density Supersonic Decelerator (LDSD) Test Vehicle Spin Motors Sub-System

Future missions to Mars will require improved entry, descent, and landing (EDL) technology over the Viking-heritage systems which recently landed the largest payload to date, the 900 kg Mars Science Laboratory. As a result, NASA's Low Density Supersonic Decelerator (LDSD) project is working to advance the state of the art in Mars EDL systems by developing and testing three key technologies which will enable heavier payloads and higher altitude landing sites on the red planet. These technologies consist of a large 33.5 m diameter Supersonic Disk Sail (SSDS) parachute and two different Supersonic Inflatable Aerodynamic Decelerator (SIAD) devices - a robotic class that inflates to a 6 m diameter torus (SIAD-R), and an exploration class that inflates to an 8 m diameter isotensoid (SIADE). All three technologies will be demonstrated on test vehicles at high earth altitudes in order to simulate the Mars EDL environment. Each vehicle will be carried to altitude by a large helium balloon, released, spun up using spin motors to stabilize the vehicle's trajectory, and accelerated to supersonic speeds using a large solid rocket motor. The vehicle will then be spun down using another set of spin motors, and will deploy either the SIAD-R or SIAD-E, followed by the SSDS parachute until the vehicle lands in the ocean. Component level testing and bounding analysis are used to ensure the survival of system components in extreme thermal environments and predict temperatures throughout the flight. This paper presents a general description of the thermal testing, model correlation, and analysis of the spin motor passive thermal control sub-system to maintain spin motor performance, prescribed vehicle trajectory, and structural integrity of the test vehicle. The spin motor subsystem is predicted to meet its requirements with margin.

thermal analysis↗

NASA NTRS2016

Investigation of Secondary Neutron Production in Large Space Vehicles for Deep Space

Future NASA missions will focus on deep space and Mars surface operations with large structures necessary for transportation of crew and cargo. In addition to the challenges of manufacturing these large structures, there are added challenges from the space radiation environment and its impacts on the crew, electronics, and vehicle materials. Primary radiation from the sun (solar particle events) and from outside the solar system (galactic cosmic rays) interact with materials of the vehicle and the elements inside the vehicle. These interactions lead to the primary radiation being absorbed or producing secondary radiation (primarily neutrons). With all vehicles, the high-energy primary radiation is of most concern. However, with larger vehicles, there is more opportunity for secondary radiation production, which can be significant enough to cause concern. In a previous paper, we embarked upon our first steps toward studying neutron production from large vehicles by validating our radiation transport codes for neutron environments against flight data. The following paper will extend the previous work to focus on the deep space environment and the resulting neutron flux from large vehicles in this deep space environment.

Rojdev, Kristina↗

NASA NTRS2016

Development of Constraint Force Equation Methodology for Application to Multi-Body Dynamics Including Launch Vehicle Stage Seperation

The objective of this report is to develop and implement a physics based method for analysis and simulation of multi-body dynamics including launch vehicle stage separation. The constraint force equation (CFE) methodology discussed in this report provides such a framework for modeling constraint forces and moments acting at joints when the vehicles are still connected. Several stand-alone test cases involving various types of joints were developed to validate the CFE methodology. The results were compared with ADAMS(Registered Trademark) and Autolev, two different industry standard benchmark codes for multi-body dynamic analysis and simulations. However, these two codes are not designed for aerospace flight trajectory simulations. After this validation exercise, the CFE algorithm was implemented in Program to Optimize Simulated Trajectories II (POST2) to provide a capability to simulate end-to-end trajectories of launch vehicles including stage separation. The POST2/CFE methodology was applied to the STS-1 Space Shuttle solid rocket booster (SRB) separation and Hyper-X Research Vehicle (HXRV) separation from the Pegasus booster as a further test and validation for its application to launch vehicle stage separation problems. Finally, to demonstrate end-to-end simulation capability, POST2/CFE was applied to the ascent, orbit insertion, and booster return of a reusable two-stage-to-orbit (TSTO) vehicle concept. With these validation exercises, POST2/CFE software can be used for performing conceptual level end-to-end simulations, including launch vehicle stage separation, for problems similar to those discussed in this report.

Pamadi, Bandu N.↗

NASA NTRS2016

Performance Efficient Launch Vehicle Recovery and Reuse

For decades, economic reuse of launch vehicles has been an elusive goal. Recent attempts at demonstrating elements of launch vehicle recovery for reuse have invigorated a debate over the merits of different approaches. The parameter most often used to assess the cost of access to space is dollars-per-kilogram to orbit. When comparing reusable vs. expendable launch vehicles, that ratio has been shown to be most sensitive to the performance lost as a result of enabling the reusability. This paper will briefly review the historical background and results of recent attempts to recover launch vehicle assets for reuse. The business case for reuse will be reviewed, with emphasis on the performance expended to recover those assets, and the practicality of the most ambitious reuse concept, namely propulsive return to the launch site. In 2015, United Launch Alliance (ULA) announced its Sensible, Modular, Autonomous Return Technology (SMART) reuse plan for recovery of the booster module for its new Vulcan launch vehicle. That plan employs a non-propulsive approach where atmospheric entry, descent and landing (EDL) technologies are utilized. Elements of such a system have a wide variety of applications, from recovery of launch vehicle elements in suborbital trajectories all the way to human space exploration. This paper will include an update on ULA's booster module recovery approach, which relies on Hypersonic Inflatable Aerodynamic Decelerator (HIAD) and Mid-Air Retrieval (MAR) technologies, including its concept of operations (ConOps). The HIAD design, as well as parafoil staging and MAR concepts, will be discussed. Recent HIAD development activities and near term plans including scalability, next generation materials for the inflatable structure and heat shield, and gas generator inflation systems will be provided. MAR topics will include the ConOps for recovery, helicopter selection and staging, and the state of the art of parachute recovery systems using large parafoils for space asset recovery and high altitude deployment. The next proposed HIAD flight demonstration is called HULA (for HIAD on ULA), and will feature a 6m diameter HIAD. An update for the HULA concept will be provided in this paper. As proposed, this demonstration will fly as a secondary payload on an Atlas mission. The Centaur upper stage provides the reentry pointing, deorbit burn, and entry vehicle spin up. The flight test will culminate with a recovery of the HIAD using MAR. HULA will provide data from a Low Earth Orbit (LEO) return aeroheating environment that enables predictive model correlation and refinement. The resultant reduction in performance uncertainties should lead to design efficiencies that are increasingly significant at larger scales. Relevance to human scale Mars EDL using a HIAD will also be presented, and the applicability of the data generated from both HULA and SMART Vulcan flights, and its value for NASA's human exploration efforts will be discussed. A summary and conclusion will follow.

Reed, John G.↗

NASA NTRS2016

Fire Detection Tradeoffs as a Function of Vehicle Parameters

Fire survivability depends on the detection of and response to a fire before it has produced an unacceptable environment in the vehicle. This detection time is the result of interplay between the fire burning and growth rates; the vehicle size; the detection system design; the transport time to the detector (controlled by the level of mixing in the vehicle); and the rate at which the life support system filters the atmosphere, potentially removing the detected species or particles. Given the large differences in critical vehicle parameters (volume, mixing rate and filtration rate) the detection approach that works for a large vehicle (e.g. the ISS) may not be the best choice for a smaller crew capsule. This paper examines the impact of vehicle size and environmental control and life support system parameters on the detectability of fires in comparison to the hazard they present. A lumped element model was developed that considers smoke, heat, and toxic product release rates in comparison to mixing and filtration rates in the vehicle. Recent work has quantified the production rate of smoke and several hazardous species from overheated spacecraft polymers. These results are used as the input data set in the lumped element model in combination with the transport behavior of major toxic products released by overheating spacecraft materials to evaluate the necessary alarm thresholds to enable appropriate response to the fire hazard.

microgravity↗

NASA NTRS2016

Fire Detection Tradeoffs as a Function of Vehicle Parameters

microgravity↗