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Re-Usable Launch and Payload Delivery System MDDP 2012/3

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Re-Usable Launch and Payload Delivery System MDDP 2012/3 Group 2 Re-usable Launch and Payload Delivery System MDDP 2012/3 Re-usable Launch and Payload Delivery System MDDP Group 2 James Dobberson Robert Taylor Matthew Chapman Timothy West Mukudzei Muchengeti William Wou Group 2 Re-usable Launch and Payload Delivery System MDDP 2012/3 1. Contents 1. Contents ..................................................................................................................................... i 2. Executive Summary .................................................................................................................. ii 3. Introduction .............................................................................................................................. 1 4. Down Selection and Integration Methodology ......................................................................... 2 5. Presentation of System Concept and Operations ...................................................................... 5 6. System Investment Plan ......................................................................................................... 20 7. Numerical Analysis and Statement of Feasibility .................................................................. 23 8. Conclusions and Future Work ................................................................................................ 29 9. Launch Philosophy ................................................................................................................. 31 10. Propulsion ............................................................................................................................... 42 11. Structures and Fuel Systems ................................................................................................... 51 12. Materials ................................................................................................................................. 62 13. In Orbit Operations ................................................................................................................. 69 14. Electronics .............................................................................................................................. 75 15. Re-Entry ................................................................................................................................. 91 16. Landing ................................................................................................................................. 103 17. Payload and Markets ............................................................................................................ 110 18. Component Mass Estimation ................................................................................................ 128 19. Infrastructure ........................................................................................................................ 129 20. Finance ................................................................................................................................. 141 21. Sensitivity Analysis .............................................................................................................. 148 22. References ................................................................................................................................. i 23. Appendices ............................................................................................................................ A1 A. Launch Philosophy Appendix ............................................................................................... A1 B. Propulsion Appendix ............................................................................................................. B1 C. Structures and Materials Appendix ....................................................................................... C1 D. In Orbit Operations and Electronics ...................................................................................... D1 E. Re-entry Appendix .................................................................................................................E1 F. Landing Appendix .................................................................................................................. F1 G. Payloads and Markets Appendix ........................................................................................... G1 H. Mass Estimating Relationships .............................................................................................. H1 I. Project Management ................................................................................................................ I1 Section ‎1 - Contents Page i Group 2 Re-usable Launch and Payload Delivery System MDDP 2012/3 2. Executive Summary This report examines the feasibility of producing and operating a new reusable launch system to deliver payloads to a Low Earth Orbit by consideration of the technical and financial viability of such a system over a typical service life. Since the Space Shuttle was retired by NASA there has not been a reusable launch system available to the commercial market. Since‎the‎1960’s‎when‎the‎ early design work for the shuttle program began, many in the space industry have believed that a highly reusable payload delivery system could be more financially viable than a traditional expendable rocket; however such a system has yet to be realised. For this feasibility study a conceptual design for a reusable payload delivery system was developed; this was done by comparing all the possible options for each subsystem to find the most suitable solution to the design criteria. The comparison was undertaken using a down selection process which defined a set of criteria that were used compare the subsystem solutions. The criteria used for the down selection were technical viability, financial feasibility, development program risk, concept integration, environmental impact and system reusability. From these criteria it was possible to find the most suitable collection of subsystems that offered the most viable design approach. Once the most suitable solution had been proposed for each subsystem, these solutions were integrated into a conceptual design to prove that a viable payload delivery system could be created. The integration phase allowed the solutions from the down selection process to be formed into a conceptual design which could then be financially analysed. The key design areas of a reusable space vehicle were examined to develop the system concept and concept of operations. Analysis of Launch Philosophy and Propulsion lead to the selection of a traditional vertical launch rocket over other concepts such as a Single Stage to Orbit space plane or an Air Launched expendable rocket system. To best satisfy the markets outlined in the Inception Report the rocket was optimised during the integration phase to a two rocket system family. The A-variant able to lift payloads of 25,000kg using two stages and the B- Variant able to lift payloads of 40,000kg using three stages. Both variants have an extremely high degree of commonality using common engines and a common first stage.‎ The‎ rocket‎ engines’‎ cores‎ are‎ common to all of the rocket stages in both variants, although the first stage uses thrust augmentation nozzles to increase the efficiency of the rocket engines when they are operating within‎ earth’s‎ atmosphere.‎ The‎ A-Variant would be capable of carrying a human module containing 10 passengers and a safety system and would be evolved into a 25 passenger module later in the operational life. Both A and B variants would be able to carry unmanned payloads, such as satellites. The optimal structural solution was found to be a semi-monocoque structure that incorporates stringers and long runs to increase the stiffness and reduce the likelihood of failure through buckling. The fuel within the fuels tanks would need to be controlled and stored correctly to make sure that the fuel travels through the fuel lines to the engines and to ensure that Section ‎2 - Executive Summary Page ii Group 2 Re-usable Launch and Payload Delivery System MDDP 2012/3 it does not slosh, altering the vehicles centre of mass during operations. The spacecraft electronics are responsible for controlling and monitoring the system. The electronics subsystems are linked using a SpaceWire communication bus. Each subsystem would contain a high level of redundancy, including at least 3 field programmable gate arrays to ensure that the subsystems can be controlled even if failures do occur. The system monitoring subsystem would allow data to be collected on the integrity of the spacecraft, increasing reliability and reusability. The system would take off vertically from the launch pad at a site close to the equator and travel east as this would provide the most efficient method of achieving a 200km Orbit. Once the spacecraft has achieved orbit it can complete an orbit transfer to the higher orbit as required by individual missions. Once the mission has been completed some payloads (such as humans) may need to be returned to earth. All modules that re-enter the‎earth’s‎atmosphere, including reusable stages, would be subjected to a ballistic re-entry profile, the aerodynamic drag causing the heat shield surface to increase in temperature as the crafts velocity is reduced. Once the craft has decelerated, thrusters would be used to land the craft at the launch site using the same thrusters form the launch emergency escape system. Once the vehicle has returned to the
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