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Air Launch System

Air Launch System. Preliminary Design Review April 7, 2008. Dan Poniatowski (Team Lead) Matt Campbell Dan Cipera Pierre Dumas Boris Kaganovich Jason LaDoucer Isaac Landecker Brandon Miller Long Nguyen Rizwan Qureshi Angela Reesman Cory Sorenson. 1. Project Overview.

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Air Launch System

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  1. Air Launch System Preliminary Design Review April 7, 2008 Dan Poniatowski (Team Lead) Matt Campbell Dan Cipera Pierre Dumas Boris Kaganovich Jason LaDoucer Isaac Landecker Brandon Miller Long Nguyen Rizwan Qureshi Angela Reesman Cory Sorenson 1

  2. Project Overview • Goals and Motivation • Design a multi-stage vehicle that is launched from high altitude and is capable of delivering a small payload to the ISS. • The vehicle must be readily available, simple to use and require a minimum amount of preparation prior to launch. • The motivation is to reduce the cost and improve reliability of launching a small payload into orbit by using an aircraft as the first lifting stage instead of a rocket. • Scope and Deliverables • Produce a Solid Works model of each system component. This includes the aircraft launch system, booster assembly and satellite. • Use a variety of techniques including theory, Solid Works, Joe Mueller’s orbital mechanics code and Professor Hammer’s thermal analysis code to ensure the system can accomplish its mission.

  3. Project Overview - Organization

  4. Project Overview – Major Tasks Trade Studies - Provide specifications, pros and cons of many options. This includes carrier aircraft, boosters and satellite components. Percent Complete: 100% • Aircraft Analysis Tasks • Select a carrier aircraft • Design delivery and release mechanism for the booster • Produce SolidWorks models of all components. Percent Complete: 95%

  5. Project Overview – Major Tasks • Booster Design Tasks • Select the rocket motors used by the booster • Run gravity turn simulations usign Joe Mueller’s code • Produce a SolidWorks model of the booster assembly. Percent Complete: 90% • Satellite Design Tasks • Find Delta-v required for station keeping • Estimation of disturbance forces • SolidWorks models of the satellite assembly • Determine hardware components • Performing thermal analysis • Determining power requirements Percent Complete: 60%

  6. Aircraft Team Spring Semester April 7, 2008 Presenter Names: Matt Campbell, Isaac Landecker, Dan Cipera, Brandon Miller

  7. Overview • Requirements • Aircraft Analysis Trade Study • AIAA Trade Study • Delivery Method • Direction • “The Exit” • Drop Dynamics • Parachutes • Requirements Completed Sarigul-Klijn 1

  8. Requirements • Identify several potential carrier aircraft and determine the key performance metrics: • Aircraft Compatibility • Maximum takeoff weight • Derive maximum dimensions and mass of launch vehicle • Derive the maximum flight path angle as a function of launch vehicle mass, altitude, velocity

  9. Requirements • Perform structural analysis for attachments • Compare with loads associated with missiles / bombs for which the aircraft is already designed to carry • Design attachment structure and release mechanism Old Designs

  10. The Plan • Compare and contrast different possibilities for launch aircraft • Three Categories: Commercial, American Military, and Foreign Military • Determine which aircraft could meet the project requirements, and of those, select the one with best balance between performance, availability, and cost.

  11. Aircraft Considered • Commercial: Boeing 777, Boeing 747-400, Airbus A330, Lockheed L-1011 • US Military: F-15, F-16 F-22, B-1B, B-2, B-52, C-5, C-17 • Foreign Military • European: Eurofighter, Rafale, Tornado • Russian: MiG-29, Su-27, Tu-22M, Tu-95, An-124

  12. Parameters Considered • Performance: MTOW, Service Ceiling, Range, Payload capabilities • Availability: production status, numbers produced, locations available • Cost: cost of production for a new airframe

  13. AIAA-2005-0621 Trade Study

  14. Internally Mounted Rocket

  15. Best Methods of the Trade Study • Launch Direction: Forward Facing Launch • Increased payload by 30% compared with ground launch • Orientation: Stabilizing Parachute • Lightweight and reliable system • Extraction: Gravity Air Launch • Simple and reliable • Loads up to 60,000 lbs. have been demonstrated • 5 to 7 degree angle of attack • Carriage: Wheels and Pneumatic Tires • Low cost and reliable • No point loads on launch vehicle

  16. The Choice • C-17 • Payload Capability =76,657 kg • Availability > 134 aircraft world wide • Cost ($/hr) = ~ $6,000 • In-air-refueling • Cargo Area

  17. Delivery Method • Structure • Able to withstand 1.5 G’s of force on structure • Maintains a Safety Factors of 1.5 • Designed to withstand 30,000 N w/ 1.5 S.F. • Ramp • Total Weight • ~9,000 kg • Entire Wheel System weighs 36 kg a piece

  18. Delivery Method • Wheels (R=0.4 m, t=0.22 m, P=135 kPa) • allow for constant pressure along rocket • Wheels are large enough to withstand pressure • No point loads • Large enough to dampen wheel frequency • Single flat tire will not cause any problems

  19. The Ramp

  20. The Wheel Assembly

  21. Wheel Assembly Displacement Nodal Stress

  22. Air Launch LLC Drop Footage (Source: www.airlaunchllc.com) The Drop

  23. Drop Dynamics • Assumptions • Dimensions • Cargo Bay • Ramp • Rocket • Determine parachute required

  24. Drop Dynamics • Drogue Parachute • 4ft diameter • Cd = 1.0 • Stabilizing Parachute • Mounted on top of rocket

  25. Requirements Completed • Identify several potential carrier aircraft and determine the key performance metrics: • Vertical clearance inside aircraft • Maximum takeoff weight • Derive maximum dimensions and mass of launch vehicle • Derive the maximum flight path angle as a function of launch vehicle mass, altitude, velocity • Perform structural analysis for attachments • Compare with loads associated with missiles / bombs for which the aircraft is already designed to carry • Design attachment structure and release mechanism

  26. Sources Sarigul-Klijn, Marti. Sarigul-Klijn, Nesrin. Hudson, Gary. Mckinney, Bevin. Menzel, Lyle. Grabow, Eric, “Trade Studies for Air Launching a Small Launch Vehicle from a Cargo Aircraft.” AIAA 21 June 2005: 1-12.

  27. Booster Team Spring Semester April 7, 2008 Presenter Names: Boris Kaganovich, Angela Reesman, Pierre Dumas, Rizwan Qureshi 27

  28. Design Goals Multi-stage booster for air launch application Minimum number of staging events to maximize overall system reliability Solid lower stage(s) for system launch readiness Liquid or hybrid upper stage for engine restart and more accurate orbit insertion Green propellants to simplify booster handling Fast launch readiness requires all propellants to be storable or made on-site Minimum vehicle mass to allow for wide range of carrier aircraft Minimize g-forces to allow for reduced payload mass and better payload survivability 28

  29. Booster Design Process Prepared drag free model using Excel to simplify hand calculations of booster Delta V capability. Performed trade studies for commercially available: Hybrid rocket motors Solid rocket motors Liquid rocket motors for upper stage application 29

  30. Upper Stage Motors Results of liquid motor trade study led to: SpaceX Kestrel 2 upper stage rocket motor Pressure-fed LOX-RP1 rocket motor 52kg motor and nozzle Isp of 330s Flight-proven design Currently in serial production 30

  31. Booster Design • 3 stage booster • 1st stage: ATK Orion 50XL solid motor • 2nd stage: ATK Star 31 solid motor • 3rd stage: SpaceX Kestrel 2 LOX-RP1 pressure-fed liquid motor • Based on drag free model in the spreadsheet : • 25kg payload • 345 kg 3rd stage propellant • 8.63 km/s total Delta V • 6298 kg takeoff mass 31

  32. Gravity Turn Simulations Launch Flight Path Angle: 87.97 deg. • Used Joe Mueller’s Matlab code to simulate gravity turn • Parameters that can be varied in code: • Flight Path Angle (FPA) • Height at which ignition 3 starts • Mass of Stage 3 Propellant

  33. Launch trajectory • Simulations produced the following direct launch trajectory to reach ISS: 33

  34. 3D Orbit Matlab simulation produced the following orbit: 34

  35. Further orbit simulations Satellite Tool Kit (STK) initial orbit simulations: 35

  36. Satellite Team Spring Semester April 7, 2008 Presenter Names: Long Nguyen, Cory Sorenson, Jason LaDoucer 36

  37. Major Requirements – Upper Stage Satellite • To deliver a one cubic foot, 2.2 lb package to ISS • Compute the delta-v required for station-keep with the ISS • Compute the minimum fuel required for station-keep • Perform initial sizing of upper stage satellite • Develop a basic CAD model of upper stage satellite

  38. Motivation for satellite design • Reduce total mass required for launch • Lightweight • Low power consumption • Minimize volume • Minimize error

  39. Trade Studies • Necessary Components • Processor board • Communication module • Attitude sensor & control • Inertial Measurement Unit • PRISMA (Swedish Satellite)

  40. PRISMA Trade Study • Small experimental Swedish satellite • Designed for close range maneuvers • 140kg • 8 months • Has similar design features • Capable of performing necessary maneuvers

  41. Final Components • LEON3 Processor board on a chip by • Volts Required – 3.3 V • Weight – 50 g • SSTL S-band module • Volt Required – 28 V • Weight – 1000 g Picture Source: http://www.sstl.co.uk /documents/S-Band%20Receiver.pdf

  42. Final Components (Cont.) • MIMU by Honeywell • Volts Required – 28 V • Weight 4700 g • Bias 0.005 deg/hr • MiDES (Mini Dual Earth Sensor) by Servo • Volts Required – 28 V • Weight – 1500 g • Accuracy – 0.04 deg Picture source:http://www.servo.com /Mides%20LEO%20Brochure1.pdf

  43. Micro thruster • Volt Required – 5 V • Weight – 70 g • Thrust capability of 0.5 to 2.3 N • Thrust variable • Approximately 6 thrusters Picture source: http://www.marotta.com/pdf/cold-gas-micro-thruster-article.pdf

  44. CAD - Satellite

  45. Satellite Maneuvers • Changing orbit to match ISS • Delta V ~5.5m/s • Chase Maneuver • Large delta V • Phasing with ISS • Main Drivers • Fuel • Time

  46. Phasing With ISS

  47. Satellite Environment • Did trade study to determine thermal/radiation environment and space debris • Using 90 minute orbital period, satellite exposed to sunlight side (395K) more so than dark side (173K) • Satellite in LEO within inner Van Allen radiation belt • Protection from space debris, UV radiation • Aluminized Mylar • Passive Thermal Control

  48. Required Δv for station keep • Determined area of ISS (768 + 192 m2) • Ran simulations with Joe Mueller’s MATLAB code using three shapes (square, sphere, bullet) • Determined sensitivity of parameters (navigation, thruster Isp, areas) • Navigation errors (accuracy of position sensors) contribute the most to Δv • With single thruster, Δv required for mission (30 days) < 15.2 m/s or 2.2% of satellite mass

  49. Structural Analysis of Satellite Casing

  50. Things to finish • Determine mass of satellite with thermal protection • Run simulations to determine fuel requirements with known mass thruster selection and how many thrusters • Run simulations to determine stress and strain for known mass

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