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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

A New Handbook for the Development of Space Vehicle Terrestrial Environment Design Requirements

A new NASA document entitled "Terrestrial Environment (Climatic) Criteria Handbook for Use in Aerospace Vehicle Development (NASA-HDBK-IOO1A) has been developed. The Handbook provides terrestrial environment information, data bases, models, recommendations, etc. for use in the design, development, trade studies, testing, and mission analyses for space (or launch) vehicles. This document is organized into fourteen specific natural environment disciplines of which some are winds, atmospheric models, thermal radiation, precipitation-for-icing, cloud cover, atmospheric electricity, geologic hazards, toxic chemical release by propulsion systems, and sea state. Atmospheric phenomena play a significant role in the design and flight of aerospace vehicles and in the integrity of the associated aerospace systems and structures. Environmental design criteria guidelines in this document are based on measurements and observations of atmospheric and climatic phenomena relative to various aerospace development, operational, and vehicle launch locations. The natural environment criteria guidelines data presented in this Handbook were formulated based on discussions with and requests from engineers involved in aerospace vehicle development and operations. Therefore, they represent responses to actual engineering problems and are not just a general compilation of environmental data. The Handbook addresses the basis for the information presented, the interpretations of the terrestrial environment guideline given in the Handbook, and its application to the development of aerospace vehicle design requirements. Specific examples of the Handbook content and associated "lessons lenmed" are given in this paper.

Johnson, Dale L.↗

NASA NTRS2008

NASA Experience with Pogo in Human Spaceflight Vehicles

An overview of more than 45 years of NASA human spaceflight experience is presented with respect to the thrust axis vibration response of liquid fueled rockets known as pogo. A coupled structure and propulsion system instability, pogo can result in the impairment of the astronaut crew, an unplanned engine shutdown, loss of mission, or structural failure. The NASA history begins with the Gemini Program and adaptation of the USAF Titan II ballistic missile as a spacecraft launch vehicle. It continues with the pogo experienced on several Apollo-Saturn flights in both the first and second stages of flight. The defining moment for NASA s subsequent treatment of pogo occurred with the near failure of the second stage on the ascent of the Apollo 13 mission. Since that time NASA has had a strict "no pogo" philosophy that was applied to the development of the Space Shuttle. The "no pogo" philosophy lead to the first vehicle designed to be pogo-free from the beginning and the first development of an engine with an integral pogo suppression system. Now, more than 30 years later, NASA is developing two new launch vehicles, the Ares I crew launch vehicle propelling the Orion crew excursion vehicle, and the Ares V cargo launch vehicle. A new generation of engineers must again exercise NASA s system engineering method for pogo mitigation during design, development and verification.

Larsen, Curtis E.↗

NASA NTRS2008

Integrated Vehicle Ground Vibration Testing of Manned Spacecraft: Historical Precedent

For the first time in nearly 30 years, NASA is developing a new manned space flight launch system. The Ares I will carry crew and cargo to not only the International Space Station, but onward for the future exploration of the Moon and Mars. The Ares I control system and structural designs use complex computer models for their development. An Integrated Vehicle Ground Vibration Test (IVGVT) will validate the efficacy of these computer models. The IVGVT will reduce the technical risk of unexpected conditions that could place the vehicle or crew in jeopardy. The Ares Project Office's Flight and Integrated Test Office commissioned a study to determine how historical programs, such as Saturn and Space Shuttle, validated the structural dynamics of an integrated flight vehicle. The study methodology was to examine the historical record and seek out members of the engineering community who recall the development of historic manned launch vehicles. These records and interviews provided insight into the best practices and lessons learned from these historic development programs. The information that was gathered allowed the creation of timelines of the historic development programs. The timelines trace the programs from the development of test articles through test preparation, test operations, and test data reduction efforts. These timelines also demonstrate how the historical tests fit within their overall vehicle development programs. Finally, the study was able to quantify approximate staffing levels during historic development programs. Using this study, the Flight and Integrated Test Office was able to evaluate the Ares I Integrated Vehicle Ground Vibration Test schedule and workforce budgets in light of the historical precedents to determine if the test had schedule or cost risks associated with it.

Lemke, Paul R.↗

NASA NTRS2008

Refinements in the Design of the Ares V Cargo Launch Vehicle for NASA's, Exploration Strategy

NASA is developing a new launch vehicle fleet to fulfill the national goals of replacing the shuttle fleet, completing the International Space Station (ISS), and exploring the Moon on the way to eventual exploration of Mars and beyond. Programmatic and technical decisions during early architecture studies and subsequent design activities were focused on safe, reliable operationally efficient vehicles that could support a sustainable exploration program. A pair of launch vehicles was selected to support those goals the Ares I crew launch vehicle and the Ares V cargo launch vehicle. They will be the first new human-rated launch vehicles developed by NASA in more than 30 years (Figure 1). Ares I will be the first to fly, beginning space station ferry operations no later than 2015. It will be able to carry up to six astronauts to ISS or support up to four astronauts for expeditions to the moon. Ares V is scheduled to be operational in the 2020 timeframe and will provide the propulsion systems and payload to truly extend human exploration beyond low-Earth orbit. (LEO).

Creech, Steve↗

NASA NTRS2008

Visualization Component of Vehicle Health Decision Support System

The visualization front-end of a Decision Support System (DSS) also includes an analysis engine linked to vehicle telemetry, and a database of learned models for known behaviors. Because the display is graphical rather than text-based, the summarization it provides has a greater information density on one screen for evaluation by a flight controller.This tool provides a system-level visualization of the state of a vehicle, and drill-down capability for more details and interfaces to separate analysis algorithms and sensor data streams. The system-level view is a 3D rendering of the vehicle, with sensors represented as icons, tied to appropriate positions within the vehicle body and colored to indicate sensor state (e.g., normal, warning, anomalous state, etc.). The sensor data is received via an Information Sharing Protocol (ISP) client that connects to an external server for real-time telemetry. Users can interactively pan, zoom, and rotate this 3D view, as well as select sensors for a detail plot of the associated time series data. Subsets of the plotted data can be selected and sent to an external analysis engine to either search for a similar time series in an historical database, or to detect anomalous events. The system overview and plotting capabilities are completely general in that they can be applied to any vehicle instrumented with a collection of sensors. This visualization component can interface with the ISP for data streams used by NASA s Mission Control Center at Johnson Space Center. In addition, it can connect to, and display results from, separate analysis engine components that identify anomalies or that search for past instances of similar behavior. This software supports NASA's Software, Intelligent Systems, and Modeling element in the Exploration Systems Research and Technology Program by augmenting the capability of human flight controllers to make correct decisions, thus increasing safety and reliability. It was designed specifically as a tool for NASA's flight controllers to monitor the International Space Station and a future Crew Exploration Vehicle.

Jacob, Joseph↗

NASA NTRS2009

Operational Considerations and Comparisons of the Saturn, Space Shuttle and Ares Launch Vehicles

The United States (U.S.) space exploration policy has directed the National Aeronautics and Space Administration (NASA) to retire the Space Shuttle and to replace it with a new generation of space transportation systems for crew and cargo travel to the International Space Station, the Moon, Mars, and beyond. As part of the Constellation Program, engineers at NASA's Marshall Space Flight Center in Huntsville, Alabama are working to design and build the Ares I, the first of two large launch vehicles to return humans to the Moon. A deliberate effort is being made to ensure a high level of operability in order to significantly increase safety and availability as well as reduce recurring costs of this new launch vehicle. It is the Ares Project's goal to instill operability as part of the requirements development, design and operations of the vehicle. This paper will identify important factors in launch vehicle design that affect the operability and availability of the system. Similarities and differences in operational constraints will also be compared between the Saturn V, Space Shuttle and current Ares I design. Finally, potential improvements in operations and operability for large launch vehicles will be addressed. From the examples presented, the paper will discuss potential improvements for operability for future launch vehicles.

Cruzen, Craig↗

NASA NTRS2010

Ares I-X Flight Test Vehicle Modal Test

The first test flight of NASA's Ares I crew launch vehicle, called Ares I-X, was launched on October 28, 2009. Ares I-X used a 4-segment reusable solid rocket booster from the Space Shuttle heritage with mass simulators for the 5th segment, upper stage, crew module and launch abort system. Flight test data will provide important information on ascent loads, vehicle control, separation, and first stage reentry dynamics. As part of hardware verification, a series of modal tests were designed to verify the dynamic finite element model (FEM) used in loads assessments and flight control evaluations. Based on flight control system studies, the critical modes were the first three free-free bending mode pairs. Since a test of the free-free vehicle was not practical within project constraints, modal tests for several configurations during vehicle stacking were defined to calibrate the FEM. Test configurations included two partial stacks and the full Ares I-X flight test vehicle on the Mobile Launcher Platform. This report describes the test requirements, constraints, pre-test analysis, test execution and results for the Ares I-X flight test vehicle modal test on the Mobile Launcher Platform. Initial comparisons between pre-test predictions and test data are also presented.

Buehrle, Ralph D.↗

NASA NTRS2010

Space Operations for a New Era of Exploration Launch Vehicles

NASA's Constellation Program is depending on the Ares Projects to deliver the crew and cargo launch capabilities needed to send human explorers to the Moon and beyond. Ares I and V will provide the core space launch capabilities needed to continue providing crew and cargo access to the International Space Station (ISS), and to build upon the U.S. history of human space exploration. Since 2005, Ares has made substantial progress on designing, developing, and testing the Ares I crew launch vehicle and has continued its in-depth studies of the Ares V cargo launch vehicles. The combined Ares I/Ares V architecture has been designed to reduce the complexity and labor intensity of ground operations for America's next journeys beyond low-Earth orbit (LEO). A deliberate effort is being made to ensure a high level of system operability to significantly increase safety and system availability as well as reduce recurring costs for this new launch vehicle. The Ares Projects goal is to instill operability as part of the vehicles requirements development, design, and operations. This simplicity will come from using simpler, proven engine designs, as in the case of the J-2X upper stage engine and RS-68 engine; improving existing hardware, as in the case of the Shuttle-heritage 5-segment solid rocket motor; and using common propulsion and instrument unit elements between Ares I and Ares V. Furthermore, lessons learned while developing Ares I will be applied directly to Ares V operations. In 2009, the Ares Projects plan to conduct the first flight test of Ares I, designated Ares I-X. Ares I-X preparations have already prompted changes to the vehicle stacking and launch infrastructure at Kennedy Space Center (KSC), including removing Shuttle-specific fixtures from the Vehicle Assembly Building (VAB) to accommodate Ares I-style stacking operations, new firing room computers and infrastructure in the VAB Launch Control Center, and new lightning protection system towers at Launch Complex 39B to accommodate the greater height of Ares I-X. In addition to lessons learned from the stacking of Ares I-X, the flight test itself promises to yield important data and operations lessons for assembling, launching, and flying Ares I.

Cook, Stephen A.↗

NASA NTRS2010

FeatherSail - The Next Generation Nano-Class Sail Vehicle

Solar sail propulsion is a concept, which will soon become a reality. Solar sailing is a method of space flight propulsion, which utilizes the light photons to propel spacecrafts through the vacuum of space. Solar sail vehicles have generally been designed to have a very large area. This requires significant time and expenditures to develop, test and launch such a vehicle. Several notable solar propulsion missions and experiments have been performed and more are still in the development stage. This concept will be tested in the near future with the launch of the NanoSail-D satellite. NanoSail-D is a nano-class satellite, less than 10kg, which will deploy a thin lightweight sheet of reflective material used to propel the satellite in its low earth orbit. The NanoSail-D solar sail design is used for the basic design concept for the next generation of nanoclass solar sail vehicles. The FeatherSail project was started to develop a solar sail vehicle with the capability to perform attitude control via rotating or feathering the solar sails. In addition to using the robust deployment method of the NanoSail-D system, the FeatherSail design incorporates other novel technologies. These technologies include deployable thin film solar arrays and low power, low temperature Silicon-Germanium electronics. Together, these three technological advancements provide a starting point for smaller class sail vehicles. These smaller solar sail vehicles provide a capability for inexpensive missions to explore beyond the realms of low earth orbit.

Alhom, Dave C.↗

NASA NTRS2010

Ares Launch Vehicle Transonic Buffet Testing and Analysis Techniques

It is necessary to define the launch vehicle buffet loads to ensure that structural components and vehicle subsystems possess adequate strength, stress, and fatigue margins when the vehicle structural dynamic response to buffet forcing functions are considered. In order to obtain these forcing functions, the accepted method is to perform wind-tunnel testing of a rigid model instrumented with hundreds of unsteady pressure transducers designed to measure the buffet environment across the desired frequency range. The buffet wind-tunnel test program for the Ares Crew Launch Vehicle employed 3.5 percent scale rigid models of the Ares I and Ares I-X launch vehicles instrumented with 256 unsteady pressure transducers each. These models were tested at transonic conditions at the Transonic Dynamics Tunnel at NASA Langley Research Center. The ultimate deliverable of the Ares buffet test program are buffet forcing functions (BFFs) derived from integrating the measured fluctuating pressures on the rigid wind-tunnel models. These BFFs are then used as input to a multi-mode structural analysis to determine the vehicle response to buffet and the resulting buffet loads and accelerations. This paper discusses the development of the Ares I and I-X rigid buffet model test programs from the standpoint of model design, instrumentation system design, test implementation, data analysis techniques to yield final products, and presents normalized sectional buffet forcing function root-mean-squared levels.

Piatak, David J.↗

NASA NTRS2011

Analysis of Separation Corridors for Visiting Vehicles from the International Space Station

The International Space Station (ISS) is a very dynamic vehicle with many operational constraints that affect its performance, operations, and vehicle lifetime. Most constraints are designed to alleviate various safety concerns that are a result of dynamic activities between the ISS and various Visiting Vehicles (VVs). One such constraint that has been in place for Russian Vehicle (RV) operations is the limitation placed on Solar Array (SA) positioning in order to prevent collisions during separation and subsequent relative motion of VVs. An unintended consequence of the SA constraint has been the impacts to the operational flexibility of the ISS resulting from the reduced power generation capability as well as from a reduction in the operational lifetime of various SA components. The purpose of this paper is to discuss the technique and the analysis that were applied in order to relax the SA constraints for RV undockings, thereby improving both the ISS operational flexibility and extending its lifetime for many years to come. This analysis focused on the effects of the dynamic motion that occur both prior to and following RV separations. The analysis involved a parametric approach in the conservative application of various initial conditions and assumptions. These included the use of the worst case minimum and maximum vehicle configurations, worst case initial attitudes and attitude rates, and the worst case docking port separation dynamics. Separations were calculated for multiple ISS docking ports, at varied deviations from the nominal undocking attitudes and included the use of two separate attitude control schemes: continuous free-drift and a post separation attitude hold. The analysis required numerical propagation of both the separation motion and the vehicle attitudes using 3-degree-of-freedom (DOF) relative motion equations coupled with rigid body rotational dynamics to generate a large set of separation trajectories.

Zaczek, Mariusz P.↗

NASA NTRS2011

Max Launch Abort System (MLAS) Pad Abort Test Vehicle (PATV) II Attitude Control System (ACS) Integration and Pressurization Subsystem Dynamic Random Vibration Analysis

In order to mitigate catastrophic failures on future generation space vehicles, engineers at the National Aeronautics and Space Administration have begun to integrate a novel crew abort systems that could pull a crew module away in case of an emergency at the launch pad or during ascent. The Max Launch Abort System (MLAS) is a recent test vehicle that was designed as an alternative to the baseline Orion Launch Abort System (LAS) to demonstrate the performance of a "tower-less" LAS configuration under abort conditions. The MLAS II test vehicle will execute a propulsive coast stabilization maneuver during abort to control the vehicles trajectory and thrust. To accomplish this, the spacecraft will integrate an Attitude Control System (ACS) with eight hypergolic monomethyl hydrazine liquid propulsion engines that are capable of operating in a quick pulsing mode. Two main elements of the ACS include a propellant distribution subsystem and a pressurization subsystem to regulate the flow of pressurized gas to the propellant tanks and the engines. The CAD assembly of the Attitude Control System (ACS) was configured and integrated into the Launch Abort Vehicle (LAV) design. A dynamic random vibration analysis was conducted on the Main Propulsion System (MPS) helium pressurization panels to assess the response of the panel and its components under increased gravitational acceleration loads during flight. The results indicated that the panels fundamental and natural frequencies were farther from the maximum Acceleration Spectral Density (ASD) vibrations which were in the range of 150-300 Hz. These values will direct how the components will be packaged in the vehicle to reduce the effects high gravitational loads.

Ekrami, Yasamin↗

NASA NTRS2011

Reconstruction of Ares I-X Integrated Vehicle Rollout Loads

The measurements taken during the Ares I-X test flight provided a unique opportunity to assess the accuracy of the models and methods used to analyze the loads and accelerations present in the planned Ares I vehicle. During the rollout of the integrated vehicle from the Vehicle Assembly Building (VAB) to the launch pad, the vehicle and its supporting structure are subjected to wind loads and the vibrations produced by the crawler-transporter (CT) that is carrying it. While the loads induced on the vehicle during this period are generally low relative to those experienced in flight, the rollout is a period of operation of primary interest to those designing both the ground support equipment and the interfaces between the launch vehicle and its supporting structure. In this paper, the methods used for reconstructing the loads during the rollout phase are described. The results generated are compared to measured values, leading to insight into the accuracy of the Ares I assessment techniques.

Chamberlain, Matthew K.↗

NASA NTRS2011

Extensions to the Dynamic Aerospace Vehicle Exchange Markup Language

The Dynamic Aerospace Vehicle Exchange Markup Language (DAVE-ML) is a syntactical language for exchanging flight vehicle dynamic model data. It provides a framework for encoding entire flight vehicle dynamic model data packages for exchange and/or long-term archiving. Version 2.0.1 of DAVE-ML provides much of the functionality envisioned for exchanging aerospace vehicle data; however, it is limited in only supporting scalar time-independent data. Additional functionality is required to support vector and matrix data, abstracting sub-system models, detailing dynamics system models (both discrete and continuous), and defining a dynamic data format (such as time sequenced data) for validation of dynamics system models and vehicle simulation packages. Extensions to DAVE-ML have been proposed to manage data as vectors and n-dimensional matrices, and record dynamic data in a compatible form. These capabilities will improve the clarity of data being exchanged, simplify the naming of parameters, and permit static and dynamic data to be stored using a common syntax within a single file; thereby enhancing the framework provided by DAVE-ML for exchanging entire flight vehicle dynamic simulation models.

Brian, Geoffrey J.↗

NASA NTRS2005

Traffic-Light-Preemption Vehicle-Transponder Software Module

A prototype wireless data-communication and control system automatically modifies the switching of traffic lights to give priority to emergency vehicles. The system, which was reported in several NASA Tech Briefs articles at earlier stages of development, includes a transponder on each emergency vehicle, a monitoring and control unit (an intersection controller) at each intersection equipped with traffic lights, and a central monitoring subsystem. An essential component of the system is a software module executed by a microcontroller in each transponder. This module integrates and broadcasts data on the position, velocity, acceleration, and emergency status of the vehicle. The position, velocity, and acceleration data are derived partly from the Global Positioning System, partly from deductive reckoning, and partly from a diagnostic computer aboard the vehicle. The software module also monitors similar broadcasts from other vehicles and from intersection controllers, informs the driver of which intersections it controls, and generates visible and audible alerts to inform the driver of any other emergency vehicles that are close enough to create a potential hazard. The execution of the software module can be monitored remotely and the module can be upgraded remotely and, hence, automatically

Bachelder, Aaron↗

NASA NTRS2011

Reconstruction of Ares I-X Integrated Vehicle Rollout Loads

Chamberlain, Matthew K.↗

NASA NTRS2011

Design Considerations for a Launch Vehicle Development Flight Instrumentation System

When embarking into the design of a new launch vehicle, engineering models of expected vehicle performance are always generated. While many models are well established and understood, some models contain design features that are only marginally known. Unfortunately, these analytical models produce uncertainties in design margins. The best way to answer these analytical issues is with vehicle level testing. The National Aeronautics and Space Administration respond to these uncertainties by using a vehicle level system called the Development Flight Instrumentation, or DFI. This DFI system can be simple to implement, with only a few measurements, or it may be a sophisticated system with hundreds of measurement and video, without a recording capability. From experience with DFI systems, DFI never goes away. The system is renamed and allowed to continue, in most cases. Proper system design can aid the transition to future data requirements. This paper will discuss design features that need to be considered when developing a DFI system for a launch vehicle. It will briefly review the data acquisition units, sensors, multiplexers and recorders, telemetry components and harnessing. It will present a reasonable set of requirements which should be implemented in the beginning of the program in order to start the design. It will discuss a simplistic DFI architecture that could be the basis for the next NASA launch vehicle. This will be followed by a discussion of the "experiences gained" from a past DFI system implementation, such as the very successful Ares I-X test flight. Application of these design considerations may not work for every situation, but they may direct a path toward success or at least make one pause and ask the right questions.

Johnson, Martin L.↗