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NASA NTRS2007

A Conceptual Aerospace Vehicle Structural System Modeling, Analysis and Design Process

A process for aerospace structural concept analysis and design is presented, with examples of a blended-wing-body fuselage, a multi-bubble fuselage concept, a notional crew exploration vehicle, and a high altitude long endurance aircraft. Aerospace vehicle structures must withstand all anticipated mission loads, yet must be designed to have optimal structural weight with the required safety margins. For a viable systems study of advanced concepts, these conflicting requirements must be imposed and analyzed early in the conceptual design cycle, preferably with a high degree of fidelity. In this design process, integrated multidisciplinary analysis tools are used in a collaborative engineering environment. First, parametric solid and surface models including the internal structural layout are developed for detailed finite element analyses. Multiple design scenarios are generated for analyzing several structural configurations and material alternatives. The structural stress, deflection, strain, and margins of safety distributions are visualized and the design is improved. Over several design cycles, the refined vehicle parts and assembly models are generated. The accumulated design data is used for the structural mass comparison and concept ranking. The present application focus on the blended-wing-body vehicle structure and advanced composite material are also discussed.

Mukhopadhyay, Vivek↗
NASA NTRS2007

Reentry Thermal Analysis of a Generic Crew Exploration Vehicle Structure

Comparative studies were performed on the heat-shielding characteristics of honeycomb-core sandwich panels fabricated with different materials for possible use as wall panels for the proposed crew exploration vehicle. Graphite/epoxy sandwich panel was found to outperform aluminum sandwich panel under the same geometry due to superior heat-shielding qualities and lower material density. Also, representative reentry heat-transfer analysis was performed on the windward wall structures of a generic crew exploration vehicle. The Apollo low Earth orbit reentry trajectory was used to calculate the reentry heating rates. The generic crew exploration vehicle has a graphite/epoxy composite honeycomb sandwich exterior wall and an aluminum honeycomb sandwich interior wall, and is protected with the Apollo thermal protection system ablative material. In the thermal analysis computer program used, the TPS ablation effect was not yet included; however, the results from the nonablation heat-transfer analyses were used to develop a "virtual ablation" method to estimate the ablation heat loads and the thermal protection system recession thicknesses. Depending on the severity of the heating-rate time history, the virtual ablation period was found to last for 87 to 107 seconds and the ablation heat load was estimated to be in the range of 86 to 88 percent of the total heat load for the ablation time period. The thermal protection system recession thickness was estimated to be in the range of 0.08 to 0.11 inches. For the crew exploration vehicle zero-tilt and 18-degree-tilt stagnation points, thermal protection system thicknesses of h = {0.717, 0.733} inches were found to be adequate to keep the substructural composite sandwich temperature below the limit of 300 F.

Ko, William L.↗
NASA NTRS2007

Preliminary Assessment of Artificial Gravity Impacts to Deep-Space Vehicle Design

Even after more than thirty years of scientific investigation, serious concerns regarding human physiological effects of long-duration microgravity exposure remain. These include loss of bone mineral density, skeletal muscle atrophy, and orthostatic hypertension, among others. In particular, "Safe Passage: Astronaut Care for Exploration Missions," states "loss of bone density, which apparently occurs at a rate of 1% per month in microgravity, is relatively manageable on the short-duration missions of the space shuttle, but it becomes problematic on the ISS [International Space Station]. ...If this loss is not mitigated, interplanetary missions will be impossible." While extensive investigations into potential countermeasures are planned on the ISS, the delay in attaining full crew complement and onboard facilities, and the potential for extending crews tours of duty threaten the timely (< 20 years!) accumulation of sufficient data for countermeasures formulation. Indeed, there is no guarantee that even with the data, a practical or sufficiently robust set of countermeasures will be forthcoming. Providing an artificial gravity (AG) environment by crew centrifugation aboard deep-space human exploration vehicles, long a staple technique of science fiction, has received surprisingly limited engineering assessment. This is most likely due to a number of factors: the lack of definitive design requirements, especially acceptable artificial gravity levels and rotation rates, the perception of high vehicle mass and performance penalties, the incompatibility of resulting vehicle configurations with space propulsion options (i.e., aerocapture), the perception of complications associated with de-spun components such as antennae and photovoltaic arrays, and the expectation of effective crew micro-gravity countermeasures. These perception and concerns may have been overstated, or may be acceptable alternatives to countermeasures of limited efficacy. This study was undertaken as an initial step to try to understand the implications of and potential solutions to incorporating artificial gravity in the design of human deep-space exploration vehicles. Of prime interest will be the mass penalties incurred by incorporating AG, along with any mission performance degradation.

Joosten, B. Kent↗
NASA NTRS2007

Crew Exploration Vehicle Ascent Abort Overview

One of the primary design drivers for NASA's Crew Exploration Vehicle (CEV) is to ensure crew safety. Aborts during the critical ascent flight phase require the design and operation of CEV systems to escape from the Crew Launch Vehicle and return the crew safely to the Earth. To accomplish this requirement of continuous abort coverage, CEV ascent abort modes are being designed and analyzed to accommodate the velocity, altitude, atmospheric, and vehicle configuration changes that occur during ascent. The analysis involves an evaluation of the feasibility and survivability of each abort mode and an assessment of the abort mode coverage. These studies and design trades are being conducted so that more informed decisions can be made regarding the vehicle abort requirements, design, and operation. This paper presents an overview of the CEV, driving requirements for abort scenarios, and an overview of current ascent abort modes. Example analysis results are then discussed. Finally, future areas for abort analysis are addressed.

Davidson, John B., Jr.↗
NASA NTRS2007

Building Operations Efficiencies into NASA's Ares I Crew Launch Vehicle Design

The U.S. Vision for Space Exploration guides the National Aeronautics and Space Administration's (NASA's) challenging missions that expand humanity's boundaries and open new routes to the space frontier. With the Agency's commitment to complete the International Space Station (ISS) and to retire the venerable Space Shuttle by 2010, the NASA Administrator commissioned the Exploration Systems Architecture Study (ESAS) in 2005 to analyze options for safe, simple, cost-efficient launch solutions that could deliver human-rated space transportation capabilities in a timely manner within fixed budget guidelines. The Exploration Launch Projects (ELP) Office, chartered by the Constellation Program in October 2005, has been conducting systems engineering studies and business planning to successively refine the design configurations and better align vehicle concepts with customer and stakeholder requirements, such as significantly reduced life-cycle costs. As the Agency begins the process of replacing the Shuttle with a new generation of spacecraft destined for missions beyond low-Earth orbit to the Moon and Mars, NASA is designing the follow-on crew and cargo launch systems for maximum operational efficiencies. To sustain the long-term exploration of space, it is imperative to reduce the $4 billion NASA typically spends on space transportation each year. This paper gives toplevel information about how the follow-on Ares I Crew Launch Vehicle (CLV) is being designed for improved safety and reliability, coupled with reduced operations costs. These methods include carefully developing operational requirements; conducting operability design and analysis; using the latest information technology tools to design and simulate the vehicle; and developing a learning culture across the workforce to ensure a smooth transition between Space Shuttle operations and Ares vehicle development.

Dumbacher, Daniel L.↗
NASA NTRS2007

Detection and enforcement of failure-to-yield in an emergency vehicle preemption system

An intersection controlled by an intersection controller receives trigger signals from on-coming emergency vehicles responding to an emergency call. The intersection controller initiates surveillance of the intersection via cameras installed at the intersection in response to a received trigger signal. The surveillance may begin immediately upon receipt of the trigger signal from an emergency vehicle, or may wait until the intersection controller determines that the signaling emergency vehicle is in the field of view of the cameras at the intersection. Portions of the captured images are tagged by the intersection controller based on tag signals transmitted by the vehicle or based on detected traffic patterns that indicate a potential traffic violation. The captured images are downloaded to a processing facility that analyzes the images and automatically issues citations for captured traffic violations.

Bachelder, Aaron↗
NASA NTRS2007

Integrated System Test Approaches for the NASA Ares I Crew Launch Vehicle

The Ares I Crew Launch Vehicle (CLV) is being developed by the U.S. National Aeronautics and Space Administration (NASA) to provide crew access to the International Space Station (ISS) and, together with the Ares V Cargo Launch Vehicle (CaLV), serves as one component of a future launch capability for human exploration of the Moon. During the system requirements definition process and early design cycles, NASA defined and began implementing plans for integrated ground and flight testing necessary to achieve the first human launch of Ares I. The individual Ares I flight hardware elements: the first stage five segment booster (FSB), upper stage, and J-2X upper stage engine, will undergo extensive development, qualification, and certification testing prior to flight. Key integrated system tests include the Main Propulsion Test Article (MPTA), acceptance tests of the integrated upper stage and upper stage engine assembly, a full-scale integrated vehicle dynamic test (IVDT), aerodynamic testing to characterize vehicle performance, and integrated testing of the avionics and software components. The Ares I-X development flight test will provide flight data to validate engineering models for aerodynamic performance, stage separation, structural dynamic performance, and control system functionality. The Ares I-Y flight test will validate ascent performance of the first stage, stage separation functionality, and a highaltitude actuation of the launch abort system (LAS) following separation. The Orion-1 flight test will be conducted as a full, un-crewed, operational flight test through the entire ascent flight profile prior to the first crewed launch.

Cockrell, Charles E., Jr.↗
NASA NTRS2008

The 2006 Kennedy Space Center Range Reference Atmosphere Model Validation Study and Sensitivity Analysis to the Performance of the National Aeronautics and Space Administration's Space Shuttle Vehicle

The Kennedy Space Center (KSC) Range Reference Atmosphere (RRA) is a statistical model that summarizes wind and thermodynamic atmospheric variability from surface to 70 km. The National Aeronautics and Space Administration's (NASA) Space Shuttle program, which launches from KSC, utilizes the KSC RRA data to evaluate environmental constraints on various aspects of the vehicle during ascent. An update to the KSC RRA was recently completed. As part of the update, the Natural Environments Branch at NASA's Marshall Space Flight Center (MSFC) conducted a validation study and a comparison analysis to the existing KSC RRA database version 1983. Assessments to the Space Shuttle vehicle ascent profile characteristics were performed by JSC/Ascent Flight Design Division to determine impacts of the updated model to the vehicle performance. Details on the model updates and the vehicle sensitivity analyses with the update model are presented.

Burns, Lee↗
NASA NTRS2007

Ares Launch Vehicles Lean Practices Case Study

The Ares launch vehicles team, managed by the Ares Projects Office (APO) at NASA Marshall Space Flight Center, has completed the Ares I Crew Launch Vehicle System Requirements Review and System Definition Review and early design work for the Ares V Cargo Launch Vehicle. This paper provides examples of how Lean Manufacturing, Kaizen events, and Six Sigma practices are helping APO deliver a new space transportation capability on time and within budget, while still meeting stringent technical requirements. For example, Lean philosophies have been applied to numerous process definition efforts and existing process improvement activities, including the Ares I-X test flight Certificate of Flight Readiness (CoFR) process, risk management process, and review board organization and processes. Ares executives learned Lean practices firsthand, making the team "smart buyers" during proposal reviews and instilling the team with a sense of what is meant by "value-added" activities. Since the goal of the APO is to field launch vehicles at a reasonable cost and on an ambitious schedule, adopting Lean philosophies and practices will be crucial to the Ares Project's long-term SUCCESS.

Doreswamy, Rajiv↗
NASA NTRS2008

The Next Giant Leap: NASA's Ares Launch Vehicles Overview

The next chapter in NASA's history also promises to write the next chapter in America's history, as the Agency makes measurable strides toward developing new space transportation capabilities that wi!! put astronauts on course to explore the Moon as the next giant leap toward the first human footprint on Mars. This paper will present top-level plans and progress being made toward fielding the Ares I crew launch vehicle in the 2013 timeframe and the Ares V cargo launch vehicle in the 2018 timeframe. It also gives insight into the objectives for the first test flight, known as the Ares I-X, which is scheduled for April 2009. The U.S. strategy to scientifically explore space will fuel innovations such as solar power and water recycling, as well as yield new knowledge that directly benefits life on Earth. For the Ares launch vehicles, NASA is building on heritage hardware and unique capabilities; as well as almost 50 years of lessons learned from the Apollo Saturn, Space Shuttle, and commercial launch vehicle programs. In the Ares I Project's inaugural year, extensive trade studies and evaluations were conducted to improve upon the designs initially recommended by the Exploration Systems Architecture Study, resulting in significant reduction of near-term and long-range technical and programmatic risks; conceptual designs were analyzed for fitness against requirements; and the contractual framework was assembled to enable a development effort unparalleled in American space flight since the Space Shuttle. The Exploration Launch Projects team completed the Ares I System Requirements Review (SRR) at the end of 2006--the first such engineering milestone for a human-rated space transportation system in over 30 years.

Cook, Stephen A.↗
NASA NTRS2008

Orion Crew Exploration Vehicle Launch Abort System Guidance and Control Analysis Overview

Aborts during the critical ascent flight phase require the design and operation of Orion Crew Exploration Vehicle (CEV) systems to escape from the Crew Launch Vehicle (CLV) and return the crew safely to the Earth. To accomplish this requirement of continuous abort coverage, CEV ascent abort modes are being designed and analyzed to accommodate the velocity, altitude, atmospheric, and vehicle configuration changes that occur during ascent. Aborts from the launch pad to early in the flight of the CLV second stage are performed using the Launch Abort System (LAS). During this type of abort, the LAS Abort Motor is used to pull the Crew Module (CM) safely away from the CLV and Service Module (SM). LAS abort guidance and control studies and design trades are being conducted so that more informed decisions can be made regarding the vehicle abort requirements, design, and operation. This paper presents an overview of the Orion CEV, an overview of the LAS ascent abort mode, and a summary of key LAS abort analysis methods and results.

Davidson, John B.↗
NASA NTRS2008

L1 Adaptive Control Law for Flexible Space Launch Vehicle and Proposed Plan for Flight Test Validation

This paper explores application of the L1 adaptive control architecture to a generic flexible Crew Launch Vehicle (CLV). Adaptive control has the potential to improve performance and enhance safety of space vehicles that often operate in very unforgiving and occasionally highly uncertain environments. NASA s development of the next generation space launch vehicles presents an opportunity for adaptive control to contribute to improved performance of this statically unstable vehicle with low damping and low bending frequency flexible dynamics. In this paper, we consider the L1 adaptive output feedback controller to control the low frequency structural modes and propose steps to validate the adaptive controller performance utilizing one of the experimental test flights for the CLV Ares-I Program.

Kharisov, Evgeny↗
NASA NTRS2008

Ares V and Future Very Large Launch Vehicles to Enable Major Astronomical Missions

The current NASA architecture planned to return humans to the lunar surface includes the Ares V heavy lift launch vehicle designed primarily to carry the Altair lunar lander and to be available before about 2020. However. the capabilities of this system (and its variants) are such that adapting the vehicle to launch very large optical systems could achieve major scientific goals that are not otherwise possible. For example, an 8-m monolith UV/visual/IR telescope appears able to be launched to the Sun-Earth L2 location by an Ares V with a 10-m fairing. Even larger apertures that are deployed or assembled in space seem possible, which may take advantage of other elements of NASA's future human spaceflight architecture. Alternatively. multiple elements of a spatial array or two or three astronomical observatories might he launched simultaneously. That is, Ares V appears to offer the astronomy communities an opportunity to put into orbit extremely capable observatories, in addition to being a key element of NASA's current architecture for human spaceflight. For the past year, a number of scientists and engineers have been eva1uating concepts for astronomical observatories that take advantage of future large launch vehicles, including the science goals of such missions and design modifications to the vehicle to enable the observatories. In parallel, members of the Solar System science communities have likewise been considering what major science goals can be achieved if new, extremely capable launch systems become available.

Thronson, Harley↗
NASA NTRS2008

Estimation of Supersonic Stage Separation Aerodynamics of Winged-Body Launch Vehicles Using Response Surface Methods

A collection of statistical and mathematical techniques referred to as response surface methodology was used to estimate the longitudinal stage separation aerodynamic characteristics of a generic, bimese, winged multi-stage launch vehicle configuration using data obtained on small-scale models at supersonic speeds in the NASA Langley Research Center Unitary Plan Wind Tunnel. The simulated Mach 3 staging was dominated by multiple shock wave interactions between the orbiter and booster vehicles throughout the relative spatial locations of interest. This motivated a partitioning of the overall inference space into several contiguous regions within which the separation aerodynamics were presumed to be well-behaved and estimable using cuboidal and spherical central composite designs capable of fitting full second-order response functions. The primary goal was to approximate the underlying overall aerodynamic response surfaces of the booster vehicle in belly-to-belly proximity to the orbiter vehicle using relatively simple, lower-order polynomial functions that were piecewise-continuous across the full independent variable ranges of interest. The quality of fit and prediction capabilities of the empirical models were assessed in detail, and the issue of subspace boundary discontinuities was addressed. The potential benefits of augmenting the central composite designs to full third order using computer-generated D-optimality criteria were also evaluated. The usefulness of central composite designs, the subspace sizing, and the practicality of fitting low-order response functions over a partitioned inference space dominated by highly nonlinear and possibly discontinuous shock-induced aerodynamics are discussed.

Erickson, Gary E.↗
NASA NTRS2008

Synthetic Vision Displays for Planetary and Lunar Lander Vehicles

Aviation research has demonstrated that Synthetic Vision (SV) technology can substantially enhance situation awareness, reduce pilot workload, improve aviation safety, and promote flight path control precision. SV, and related flight deck technologies are currently being extended for application in planetary exploration vehicles. SV, in particular, holds significant potential for many planetary missions since the SV presentation provides a computer-generated view for the flight crew of the terrain and other significant environmental characteristics independent of the outside visibility conditions, window locations, or vehicle attributes. SV allows unconstrained control of the computer-generated scene lighting, terrain coloring, and virtual camera angles which may provide invaluable visual cues to pilots/astronauts, not available from other vision technologies. In addition, important vehicle state information may be conformally displayed on the view such as forward and down velocities, altitude, and fuel remaining to enhance trajectory control and vehicle system status. The paper accompanies a conference demonstration that introduced a prototype NASA Synthetic Vision system for lunar lander spacecraft. The paper will describe technical challenges and potential solutions to SV applications for the lunar landing mission, including the requirements for high-resolution lunar terrain maps, accurate positioning and orientation, and lunar cockpit display concepts to support projected mission challenges.

Arthur, Jarvis J., III↗
NASA NTRS2008

Seal Technology for Hypersonic Vehicle and Propulsion: An Overview

Hypersonic vehicles and propulsion systems pose an extraordinary challenge for structures and materials. Airframes and engines require lightweight, high-temperature materials and structural configurations that can withstand the extreme environment of hypersonic flight. Some of the challenges posed include very high temperatures, heating of the whole vehicle, steady-state and transient localized heating from shock waves, high aerodynamic loads, high fluctuating pressure loads, potential for severe flutter, vibration, and acoustic loads and erosion. Correspondingly high temperature seals are required to meet these aggressive requirements. This presentation reviews relevant seal technology for both heritage (e.g. Space Shuttle, X-15, and X-38) vehicles and presents several seal case studies aimed at providing lessons learned for future hypersonic vehicle seal development. This presentation also reviews seal technology developed for the National Aerospace Plane propulsion systems and presents several seal case studies aimed at providing lessons learned for future hypersonic propulsion seal development.

Steinetz, Bruce M.↗
NASA NTRS2008

Lithium Battery Power Delivers Electric Vehicles to Market

Hybrid Technologies Inc., a manufacturer and marketer of lithium-ion battery electric vehicles, based in Las Vegas, Nevada, and with research and manufacturing facilities in Mooresville, North Carolina, entered into a Space Act Agreement with Kennedy Space Center to determine the utility of lithium-powered fleet vehicles. NASA contributed engineering expertise for the car's advanced battery management system and tested a fleet of zero-emission vehicles on the Kennedy campus. Hybrid Technologies now offers a series of purpose-built lithium electric vehicles dubbed the LiV series, aimed at the urban and commuter environments.

Source record↗
NASA NTRS2009

Occupant Protection during Orion Crew Exploration Vehicle Landings

The constellation program is evaluating current vehicle design capabilities for nominal water landings and contingency land landings of the Orion Crew Exploration vehicle. The Orion Landing Strategy tiger team was formed to lead the technical effort for which associated activities include the current vehicle design, susceptibility to roll control and tip over, reviewing methods for assessing occupant injury during ascent / aborts /landings, developing an alternate seat/attenuation design solution which improves occupant protection and operability, and testing the seat/attenuation system designs to ensure valid results. The EVA physiology, systems and Performance (EPSP) project is leading the effort under the authority of the Tiger Team Steering committee to develop, verify, validate and accredit biodynamics models using a variety of crash and injury databases including NASCAR, Indy Car and military aircraft. The validated biodynamics models will be used by the Constellation program to evaluate a variety of vehicle, seat and restraint designs in the context of multiple nominal and off-nominal landing scenarios. The models will be used in conjunction with Acceptable Injury Risk definitions to provide new occupant protection requirements for the Constellation Program.

Gernhardt, Michael L.↗