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This is a comprehensive systems study to examine and evaluate throttling capabilities of liquid rocket engines. The focus of this study is on engine components, and how the interactions of these components are considered for throttling applications. First, an assessment of space mission requirements is performed to determine what applications require engine throttling. A background on liquid rocket engine throttling is provided, along with the basic equations that are used to predict performance. Three engines are discussed that have successfully demonstrated throttling. Next, the engine system is broken down into components to discuss special considerations that need to be made for engine throttling. This study focuses on liquid rocket engines that have demonstrated operational capability on American space launch vehicles, starting with the Apollo vehicle engines and ending with current technology demonstrations. Both deep throttling and shallow throttling engines are discussed. Boost and sustainer engines have demonstrated throttling from 17% to 100% thrust, while upper stage and lunar lander engines have demonstrated throttling in excess of 10% to 100% thrust. The key difficulty in throttling liquid rocket engines is maintaining an adequate pressure drop across the injector, which is necessary to provide propellant atomization and mixing. For the combustion chamber, cooling can be an issue at low thrust levels. For turbomachinery, the primary considerations are to avoid cavitation, stall, surge, and to consider bearing leakage flows, rotordynamics, and structural dynamics. For valves, it is necessary to design valves and actuators that can achieve accurate flow control at all thrust levels. It is also important to assess the amount of nozzle flow separation that can be tolerated at low thrust levels for ground testing.
NASA's Propulsion and Cryogenic Advanced Development (PCAD) project is currently developing enabling propulsion technologies in support of the Exploration Initiative, with a particular focus on the needs of the Altair Project. To meet Altair requirements, several technical challenges need to be overcome, one of which is the ability for the lunar descent engine(s) to operate over a deep throttle range with cryogenic propellants. To address this need, PCAD has enlisted Northrop Grumman Aerospace Systems (NGAS) in a technology development effort associated with the TR202, a LOX/LH2 expander cycle engine driven by independent turbopump assemblies and featuring a variable area pintle injector similar to the injector used on the TR200 Apollo Lunar Module Descent Engine (LMDE). Since the Apollo missions, NGAS has continued to mature deep throttling pintle injector technology. The TR202 program has completed two phases of pintle injector testing. The first phase of testing used ablative thrust chambers and demonstrated igniter operation as well as stable performance at several power levels across the designed 10:1 throttle range. The second phase of testing was performed on a calorimeter chamber and demonstrated injector performance at various power levels (75%, 50%, 25%, 10%, and 7.5%) across the throttle range as well as chamber heat flux to show that the engine can close an expander cycle design across the throttle range. This paper provides an overview of the TR202 program. It describes the different phases of the program with the key milestones of each phase. It then shows when those milestones were met. Next, it describes how the test data was used to update the conceptual design and how the test data has created a database for deep throttling cryogenic pintle technology that is readily scaleable and can be used to again update the design once the Altair program's requirements are firm. The final section of the paper describes the path forward, which includes demonstrating continuously throttling with an actuator and pursuing a path towards integrated engine sea-level test-bed testing.
In the late 1970s, years before the Space Shuttle flew its maiden voyage, it was understood low liquid hydrogen (LH2) Net Positive Suction Pressure (NPSP) at the inlet to the Space Shuttle Main Engine (SSME) could have adverse effects on engine operation. A number of failures within both the External Tank (ET) and the Orbiter Main Propulsion System (MPS) could result in a low LH2 NPSP condition, which at extremely low levels can result in cavitation of SSME turbomachinery. Operational workarounds were developed to take advantage of the onboard crew s ability to manually throttle down the SSMEs (via the Pilot s Speedbrake/Throttle Controller), which alleviated the low LH2 NPSP condition. Manually throttling the SSME to a lower power level resulted in an increase in NPSP, mainly due to the reduction in frictional flow losses while at the lower throttle setting. Early in the Space Shuttle Program s history, the relevant Flight Rule for the Booster flight controller in Mission Control did not distinguish between ET and Orbiter MPS failures and the same crew action was taken for both. However, after a review of all Booster operational techniques following the Challenger disaster in the late 1980s, it was determined manually throttling the SSME to a lower power was only effective for Orbiter MPS failures and the Flight Rule was updated to reflect this change. The Flight Rule and associated crew actions initially called for a single throttle step to minimum power level when a low threshold for NPSP was met. As engineers refined their understanding of the NPSP requirements for the SSME (through a robust testing program), the operational techniques evolved to take advantage of the additional capabilities. This paper will examine the evolution of the Flight rule and associated procedure and how increases in knowledge about the SSME and the Space Shuttle vehicle as a whole have helped shape their development. What once was a single throttle step when NPSP decreased to a certain low threshold has now become three throttle steps, each occurring at a lower NPSP threshold. Additionally the procedure, which for early Space Shuttle missions required a Return-to-Launch-Site abort, now results in a nominal Main Engine Cut Off and no loss of mission objectives.
In the late 1970s, years before the Space Shuttle flew its maiden voyage, it was understood low liquid hydrogen (LH2) Net Positive Suction Pressure (NPSP) at the inlet to the Space Shuttle Main Engine (SSME) could have adverse effects on engine operation. A number of failures within both the External Tank (ET) and the Orbiter Main Propulsion System (MPS) could result in a low LH2 NPSP condition, which at extremely low levels can result in cavitation of SSME turbomachinery. Operational workarounds were developed to take advantage of the onboard crew s ability to manually throttle down the SSMEs (via the Pilot s Speedbrake/Throttle Controller), which alleviated the low LH2 NPSP condition. Manually throttling the SSME to a lower power level resulted in an increase in NPSP, mainly due to the reduction in frictional flow losses while at the lower throttle setting. Early in the Space Shuttle Program s history, the relevant Flight Rule for the Booster flight controllers in Mission Control did not distinguish between ET and Orbiter MPS failures and the same crew action was taken for both. However, after a review of all Booster operational techniques following the Challenger disaster in the late 1980s, it was determined manually throttling the SSME to a lower power was only effective for Orbiter MPS failures and the Flight Rule was updated to reflect this change. The Flight Rule and associated crew actions initially called for a single throttle step to minimum power level when a low threshold for NPSP was met. As engineers refined their understanding of the NPSP requirements for the SSME (through a robust testing program), the operational techniques evolved to take advantage of the additional capabilities. This paper will examine the evolution of the Flight rule and associated procedure and how increases in knowledge about the SSME and the Space Shuttle vehicle as a whole have helped shape their development. What once was a single throttle step when NPSP decreased to a certain threshold has now become three throttle steps, each occurring at a lower NPSP threshold. Additionally the procedure, which for early Space Shuttle missions required a Return-to-Launch-Site abort, now results in a nominal Main Engine Cut Off and no loss of mission objectives.
This paper describes recent advances in ion propulsion system design which promise to increase the propulsion system reliability by reducing the overall system complexity. The greatest simplification in the overall propulsion system operation is accomplished through a change in the ion engine throttling strategy. By using three grid optics it is possible to effect engine throttling at a constant beam curent over at least a 3.8 to 1 variation in input power. Throttling at a constant beam current results in a single discharge chamber operating point and eliminates the need for active propellant flow controllers and complex engine throttling software. Detailed mission analysis calculations for a CNSR mission performed using this constant beam current throttling strategy indicate only a small reduction in delivered payload and increase in required propellant relative to a conventional throttling profile based on varying the beam curent.
Liquid-Propellant Rocket Engines (LREs) are capable of on-command variable thrust or thrust modulation, an operability advantage that has been studied intermittently since the late 1930s. Throttleable LREs can be used for planetary entry and descent, space rendezvous, orbital maneuvering including orientation and stabilization in space, and hovering and hazard avoidance during planetary landing. Other applications have included control of aircraft rocket engines, limiting of vehicle acceleration or velocity using retrograde rockets, and ballistic missile defense trajectory control. Throttleable LREs can also continuously follow the most economical thrust curve in a given situation, compared to discrete throttling changes over a few select operating points. The effects of variable thrust on the mechanics and dynamics of an LRE as well as difficulties and issues surrounding the throttling process are important aspects of throttling behavior. This review provides a detailed survey of LRE throttling centered around engines from the United States. Several LRE throttling methods are discussed, including high-pressure-drop systems, dual-injector manifolds, gas injection, multiple chambers, pulse modulation, throat throttling, movable injector components, and hydrodynamically dissipative injectors. Concerns and issues surrounding each method are examined, and the advantages and shortcomings compared.
As one of the first technology development programs awarded by NASA under the Vision for Space Exploration, the Pratt & Whitney Rocketdyne (PWR) Deep Throttling, Common Extensible Cryogenic Engine (CECE) program was selected by NASA in November 2004 to begin technology development and demonstration toward a deep throttling, cryogenic engine supporting ongoing trade studies for NASA s Lunar Lander descent stage. The CECE program leverages the maturity and previous investment of a flight-proven hydrogen/oxygen expander cycle engine, the PWR RL10, to develop and demonstrate an unprecedented combination of reliability, safety, durability, throttlability, and restart capabilities in high-energy, cryogenic, in-space propulsion. The testbed selected for the deep throttling demonstration phases of this program was a minimally modified RL10 engine, allowing for maximum current production engine commonality and extensibility with minimum program cost. Four series of demonstrator engine tests have been successfully completed between April 2006 and April 2010, accumulating 7,436 seconds of hot fire time over 47 separate tests. While the first two test series explored low power combustion (chug) and system instabilities, the third test series investigated and was ultimately successful in demonstrating several mitigating technologies for these instabilities and achieved a stable throttling ratio of 13:1. The fourth test series significantly expanded the engine s operability envelope by successfully demonstrating a closed-loop control system and extensive transient modeling to enable lower power engine starting, faster throttle ramp rates, and mission-specific ignition testing. The final hot fire test demonstrated a chug-free, minimum power level of 5.9%, corresponding to an overall 17.6:1 throttling ratio achieved. In total, these tests have provided an early technology demonstration of an enabling cryogenic propulsion concept with invaluable system-level technology data acquisition toward design and development risk mitigation for future lander descent main engines.
As one of the first technology development programs awarded by NASA under the Vision for Space Exploration, the Pratt & Whitney Rocketdyne (PWR) Deep Throttling, Common Extensible Cryogenic Engine (CECE) program was selected by NASA in November 2004 to begin technology development and demonstration toward a deep throttling, cryogenic engine supporting ongoing trade studies for NASA s Lunar Lander descent stage. The CECE program leverages the maturity and previous investment of a flight-proven hydrogen/oxygen expander cycle engine, the PWR RL10, to develop technology and demonstrate an unprecedented combination of reliability, safety, durability, throttlability, and restart capabilities in a high-energy cryogenic engine. The testbed selected for the deep throttling demonstration phases of this program was a minimally modified RL10 engine, allowing for maximum current production engine commonality and extensibility with minimum program cost. Three series of demonstrator engine tests, the first in April-May 2006, the second in March-April 2007 and the third in November-December 2008, have demonstrated up to 13:1 throttling (104% to 8% thrust range) of the hydrogen/oxygen expander cycle engine. The first two test series explored a propellant feed system instability ("chug") environment at low throttled power levels. Lessons learned from these two tests were successfully applied to the third test series, resulting in stable operation throughout the 13:1 throttling range. The first three tests have provided an early demonstration of an enabling cryogenic propulsion concept, accumulating over 5,000 seconds of hot fire time over 27 hot fire tests, and have provided invaluable system-level technology data toward design and development risk mitigation for the NASA Altair and future lander propulsion system applications. This paper describes the results obtained from the highly successful third test series as well as the test objectives and early results obtained from a fourth test series conducted over March-May 2010
NASA's Propulsion and Cryogenic Advanced Development (PCAD) project is currently developing enabling propulsion technologies in support of future lander missions. To meet lander requirements, several technical challenges need to be overcome, one of which is the ability for the descent engine(s) to operate over a deep throttle range with cryogenic propellants. To address this need, PCAD has enlisted Northrop Grumman Aerospace Systems (NGAS) in a technology development effort associated with the TR202 engine. The TR202 is a LOX/LH2 expander cycle engine driven by independent turbopump assemblies and featuring a variable area pintle injector similar to the injector used on the TR200 Apollo Lunar Module Descent Engine (LMDE). Since the Apollo missions, NGAS has continued to mature deep throttling pintle injector technology. The TR202 program has completed two series of pintle injector testing. The first series of testing used ablative thrust chambers and demonstrated igniter operation as well as stable performance at discrete points throughout the designed 10:1 throttle range. The second series was conducted with calorimeter chambers and demonstrated injector performance at discrete points throughout the throttle range as well as chamber heat flow adequate to power an expander cycle design across the throttle range. This paper provides an overview of the TR202 program, describing the different phases and key milestones. It describes how test data was correlated to the engine conceptual design. The test data obtained has created a valuable database for deep throttling cryogenic pintle technology, a technology that is readily scalable in thrust level.
During some flight programs, researchers have encountered problems in the throttle response characteristics of high-performance aircraft. To study and to help solve these problems, the National Aeronautics and Space Administration Ames Research Center's Dryden Flight Research Facility (Ames-Dryden) conducted a study using a TF-104G airplane modified with a variable-response electronic throttle control system. Ames-Dryden investigated the effects of different variables on engine response and handling qualities. The system provided transport delay, lead and lag filters, second-order lags, command rate and position limits, and variable gain between the pilot's throttle command and the engine fuel controller. These variables could be tested individually or in combination. Ten research flights were flown to gather data on engine response and to obtain pilot ratings of the various system configurations. The results should provide design criteria for engine-response characteristics. The variable-response throttle components and how they were installed in the TF-104G aircraft are described. How the variable-response throttle was used in flight and some of the results of using this system are discussed.
As one of the first technology development programs awarded by NASA under the U.S. Space Exploration Policy (USSEP), the Pratt & Whitney Rocketdyne (PWR) Deep Throttling, Common Extensible Cryogenic Engine (CECE) program was selected by NASA in November 2004 to begin technology development and demonstration toward a deep throttling, cryogenic engine supporting ongoing trade studies for NASA's Lunar Lander descent stage. The CECE program leverages the maturity and previous investment of a flight-proven hydrogen/oxygen expander cycle engine, the PWR RLI0, to develop and demonstrate an unprecedented combination of reliability, safety, durability, throttlability, and restart capabilities in a high-energy, cryogenic engine. The testbed selected for the deep throttling demonstration phases of this program was a minimally modified RL10 engine, allowing for maximum current production engine commonality and extensibility with minimum program cost. Two series of demonstrator engine tests, the first in April-May 2006 and the second in March-April 2007, have demonstrated in excess of 10:1 throttling of the hydrogen/oxygen expander cycle engine. Both test series have explored a combustion instability ("chug") environment at low throttled power levels. These tests have provided an early demonstration of an enabling cryogenic propulsion concept with invaluable system-level technology data acquisition toward design and development risk mitigation for future CECE Demonstrator engine tests.
As one of the first technology development programs awarded under NASA's Vision for Space Exploration, the Pratt & Whitney Rocketdyne (PWR) Deep Throttling, Common Extensible Cryogenic Engine (CECE) program was selected by NASA in November 2004 to begin technology development and demonstration toward a deep throttling, cryogenic Lunar Lander engine for use across multiple human and robotic lunar exploration mission segments with extensibility to Mars. The CECE program leverages the maturity and previous investment of a flight-proven hydrogen/oxygen expander cycle engine, the RL10, to develop and demonstrate an unprecedented combination of reliability, safety, durability, throttlability, and restart capabilities in a high-energy, cryogenic engine. NASA Marshall Space Flight Center and NASA Glenn Research Center personnel were integral design and analysis team members throughout the requirements assessment, propellant studies and the deep throttling demonstrator elements of the program. The testbed selected for the initial deep throttling demonstration phase of this program was a minimally modified RL10 engine, allowing for maximum current production engine commonality and extensibility with minimum program cost. In just nine months from technical program start, CECE Demonstrator No. 1 engine testing in April/May 2006 at PWR's E06 test stand successfully demonstrated in excess of 10:1 throttling of the hydrogen/oxygen expander cycle engine. This test provided an early demonstration of a viable, enabling cryogenic propulsion concept with invaluable system-level technology data acquisition toward design and development risk mitigation for both the subsequent CECE Demonstrator No. 2 program and to the future Lunar Lander Design, Development, Test and Evaluation effort.
Ion thrusters are low thrust, high specific impulse devices with typical operational lifetimes of 10,000 to 30,000 hr over a range of throttling conditions. The NEXT ion thruster is the latest generation of ion thrusters under development. The NEXT ion thruster currently has a qualification level propellant throughput requirement of 450 kg of xenon, which corresponds to roughly 22,000 hr of operation at the highest input power throttling point. This paper will provide a brief review the previous life assessment predictions for various throttling conditions. A further assessment will be presented examining the anticipated accelerator grid hole wall erosion and related electron backstreaming limit. The continued assessment of the NEXT ion thruster indicates that the first failure mode across the throttling range is expected to be in excess of 36,000 hr of operation from charge exchange induced groove erosion. It is at this duration that the groove is predicted to penetrate the accelerator grid possibly resulting in structural failure. Based on these lifetime and mission assessments, a throttling approach is presented for the Long Duration Test to demonstrate NEXT thruster lifetime and validate modeling.
NASA is conducting trade studies for a new hybrid-electric aircraft concept called the SUbsonic Single Aft eNgine (SUSAN) Electrofan. The SUSAN airplane is being designed as a 180-passenger commercial airplane and is expected to fly in the 2040 time frame. The flight deck of the SUSAN airplane is envisioned to resemble a typical two person flightcrew transport. Pilot control research issues include interfaces and display state elements needed for the 17 engine hybrid-electric propulsion system. A pilot study was conducted where one, two, and three throttle handles were the independent variable in a simulation experiment. The results from the study showed that the three throttle concepts were equivalent in terms of workload, situation awareness, and thrust control. However, the pilots rated the usability of the single throttle test case to be “good” compared to the rating of “excellent” for the two- and three-throttle cases. From these results, a follow-on pilot study is described to explore a redesigned single throttle concept with associated engine display concepts.
A preliminary investigation was conducted regarding the use of throttles for emergency flight control of a multiengine aircraft. Several airplanes including a light twin-engine piston-powered airplane, jet transports, and a high performance fighter were studied during flight and piloted simulations. Simulation studies used the B-720, B-727, MD-11, and F-15 aircraft. Flight studies used the Lear 24, Piper PA-30, and F-15 airplanes. Based on simulator and flight results, all the airplanes exhibited some control capability with throttles. With piloted simulators, landings using manual throttles-only control were extremely difficult. An augmented control system was developed that converts conventional pilot stick inputs into appropriate throttle commands. With the augmented system, the B-720 and F-15 simulations were evaluated and could be landed successfully. Flight and simulation data were compared for the F-15 airplane.
A preliminary investigation was conducted regarding the use of throttles for emergency flight control of a multiengine aircraft. Several airplanes including a light twin-engine piston-powered airplane, jet transports, and a high performance fighter were studied during flight and piloted simulations. Simulation studies used the B-720, B-727, MD-11, and F-15 aircraft. Flight studies used the Lear 24, Piper PA-30, and F-15 airplanes. Based on simulator and flight results, all the airplanes exhibited some control capability with throttles. With piloted simulators, landings using manual throttles-only control were extremely difficult. An augmented control system was developed that converts conventional pilot stick inputs into appropriate throttle commands. With the augmented system, the B-720 and F-15 simulations were evaluated and could be landed successfully. Flight and simulation data were compared for the F-15 airplane.
Flight tests and simulation studies using the throttles of an F-15 airplane for emergency flight control have been conducted at the NASA Dryden Flight Research Facility. The airplane and the simulation are capable of extended up-and-away flight, using only throttles for flight path control. Initial simulation results showed that runway landings using manual throttles-only control were difficult, but possible with practice. Manual approaches flown in the airplane were much more difficult, indicating a significant discrepancy between flight and simulation. Analysis of flight data and development of improved simulation models that resolve the discrepancy are discussed. An augmented throttle-only control system that controls bank angle and flight path with appropriate feedback parameters has also been developed, evaluated in simulations, and is planned for flight in the F-15.