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Launch Vehicle Design Process: Characterization, Technical Integration, and Lessons Learned

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Launch Vehicle Design Process: Characterization, Technical Integration, and Lessons Learned NASA / TP--2001-210992 Launch Vehicle Design Process: Characterization, Technical Integration, and Lessons Learned J.C. Blair, R.S. Ryan, and L.A. Schutzenhofer AI Signal Research, Inc. W.R. Humphries, Marshall Space Flight Center, Marshall Space Flight Center, Alabama May 2001 The NASA STI Program Office...in Profile Since its founding, NASA has been dedicated to CONFERENCE PUBLICATION. Collected the advancement of aeronautics and space papers from scientific and technical conferences, science. The NASA Scientific and Technical symposia, seminars, or other meetings sponsored Information (STI) Program Office plays a key or cosponsored by NASA. part in helping NASA maintain this important role. SPECIAL PUBLICATION. Scientific, technical, or historical information from NASA programs, The NASA STI Program Office is operated by projects, and mission, often concerned with Langley Research Center, the lead center for subjects having substantial public interest. NASA's scientific and technical information. The NASA STI Program Office provides access to the TECHNICAL TRANSLATION. NASA STI Database, the largest collection of English-language translations of foreign scientific aeronautical and space science STI in the world. The and technical material pertinent to NASA's Program Office is also NASA's institutional mission. mechanism for disseminating the results of its research and development activities. These results Specialized services that complement the STI are published by NASA in the NASA STI Report Program Office's diverse offerings include creating Series, which includes the following report types: custom thesauri, building customized databases, organizing and publishing research results...even TECHNICAL PUBLICATION. Reports of providing videos. completed research or a major significant phase of research that present the results of NASA For more information about the NASA STI Program programs and include extensive data or Office, see the following: theoretical analysis. Includes compilations of significant scientific and technical data and • Access the NASA STI Program Home Page at information deemed to be of continuing reference http ://www.sti.nasa.gov value. NASA's counterpart of peer-reviewed formal professional papers but has less stringent • E-mail your question via the Internet to limitations on manuscript length and extent of help@ sti.nasa.gov graphic presentations. • Fax your question to the NASA Access Help TECHNICAL MEMORANDUM. Scientific and Desk at (301) 621-0134 technical findings that are preliminary or of specialized interest, e.g., quick release reports, • Telephone the NASA Access Help Desk at (301) working papers, and bibliographies that contain 621-0390 minimal annotation. Does not contain extensive analysis. Write to: NASA Access Help Desk CONTRACTOR REPORT. Scientific and NASA Center for AeroSpace Information technical findings by NASA-sponsored 7121 Standard Drive contractors and grantees. Hanover, MD 21076-1320 NASA/TP--2001-210992 Launch Vehicle Design Process: Characterization, Technical Integration, and Lessons Learned J.C. Blair, R.S. Ryan, and L.A. Schutzenhofer AI Signal Research, Inc. W.R. Humphries, Marshall Space Flight Center, Marshall Space Flight Center, Alabama National Aeronautics and Space Administration Marshall Space Flight Center • MSFC, Alabama 35812 May 2001 Acknowledgments Section 4.3.9 describing the Avionics Design Function was authored by James Atherton, Charles Morris, Gray Settle, and Marion Teal. Sections 4.3. I0, 4.3.11, and 4.3.12 describing the Materials and Manufacturing Design Functions were authored by Paul Schuerer. Available from: NASA Center for AeroSpace Information National Technical Information Service 7121 Standard Drive 5285 Port Royal Road Hanover, MD 21076-1320 Springfield, VA 22161 (301) 621-0390 (703) 487-4650 PREFACE The combined experience of the authors extends over 150 years. During that time, they have participated in the design activities associated with the following programs: Redstone, Saturn I, Saturn IB, Saturn Apollo, Skylab, Space Shuttle, Spacelab, Hubble Space Telescope, HEAO, Chandra, Space Station, X-33, and various payloads. At present, they are participating in training activities at Marshall Space Flight Center. In that capacity, they are active in publications, course development and teaching, process modeling, mentoring and advising, and interactive computer tools. AUTHORS' E-MAIL ADDRESSES J.C. Blair: [email protected] R.S. Ryan: [email protected] L.A. Schutzenhofer: [email protected] W.R. Humphries: [email protected] 111 o ! ....... • ! I I I ! ............. 1 | | I I I I ! {D I ................ I I "E f- Z {D X Z E a. o °_ _-._ _ Ill =: ! Figure 1. Design process overview. iv FOREWORD This report deals with the design process for launch vehicles. It extracts information from the experience of the authors, their associates, and related literature. The initial sections of the report address essential groundwork and fundamentals, and the final sections address guidance for achieving a successful design and advancing design process technology. However, the core of the report is the characterization or description of the design process itself given in section 4.3. An overview of the process description is represented in figure 1 which illustrates the main elements and connections of the process. Main elements include compartmentalization/reintegration, subsystem tree, design function planes, discipline functions, decision gates, IxI and NxN diagrams, and the process balancing act. A reader concerned specifically with the process description can go directly to section 4.3 for the detailed discussion. The description then serves as a basis for (1) understanding the design process and how its various elements interact, (2) incorporating subtleties necessary for a successful design, and (3) achieving advances in design process effectiveness and efficiency. TABLE OF CONTENTS ° INTRODUCTION ...................................................................................................................... 1.1 Motivation and Approach ............................................................................................... 1.2 Report Overview and Organization ................................................................................ 2. DESIGN PROCESS OVERVIEW ............................................................................................. 7 2.1 Top-Level Characterization ..................... ,...................................................................... 8 18 2.2 Engineering the System .................................................................................................. 2.3 Thumbnail Sketch of Process ......................................................................................... 19 3. ESSENTIALS ............................................................................................................................. 24 24 3.1 Basis of Good Engineering ............................................................................................. 3.2 Constraints ...................................................................................................................... 24 24 3.3 Derived Requirements .................................................................................................... 24 3.4 Formal Design Criteria ................................................................................................... 25 3.5 Categories of ModelinJActivities .................................................................................. 26 3.6 Analyses, Test, and Simulation ....................................................................................... 3.7 Parameter Matrix and Uncertainties ............................................................................... 27 3.8 Sensitivities ..................................................................................................................... 27 3.9 Failure Modes ................................................................................................................. 27 28 3.10 Judgments ....................................................................................................................... 28 3.11 Probing Questions .......................................................................................................... 4. DESIGN PROCESS CHARACTERIZATION .......................................................................... 31 32 4.1 Project Technical Framework ......................................................................................... 40 4.2 Technical Integration ...................................................................................................... 4.3 Characterization Model .................................................................................................. 43 150 4.4 Design Sequence ............................................................................................................. 5. PROCESS IMPROVEMENT .................................................................................................... 168 5.1 Vehicle Hardware/Software Technologies ...................................................................... 168 168 5.2 Design Process Technologies ......................................................................................... vii TABLE OF CONTENTS (continued) 6. ILLUSTRATIONS OF PROCESS ............................................................................................
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