Reusable Booster System
Briefing to the National Research Council’s Aeronautics and Space Engineering Board
28 March 2012 Andrews is a Small Agile System Integrator Reusable Booster System Andrews Space, Inc. was founded to be a catalyst in the commercialization, exploration, and development of space. The company is an affordable integrator of
aerospace systems and developer of advanced space technologies.
Experience
System Design System Responsive Space ESPA Class Solar Tactical Imaging Launch Vehicles Electric Vehicle Nanosat Responsive
and Innovative
Hardware System Integration Ballute Flight Miniature Active Satellite Simulators Experiment Guidance Units Solutions
Kistler K-1 Triplex Bigelow Genesis II ADCS Aerojet Sundancer Fault Subsystem – 2 years on orbit with no Tolerant Propulsion
Management Unit faults Controller
Avionics Flight QualifiedFlight
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Andrews Space Business Areas and Customers Reusable Booster System
Integrated Systems Products & Components • SENTRY Nanospacecraft Bus • Nanospacecraft • Avionics & Electronics • SHERPA In-space Tug • Spacecraft Reaction Wheels / CMGs • Hypersonic Platforms • Spacecraft ADCS sensors • Responsive Launch Systems • Satellite Test Beds • Ground Support Equipment
Advanced Technologies Technical Services • Advanced Thermal / Material Technologies • Systems Engineering • Deployable Technologies • Design Development & Analysis • Air Collection & Enrichment System • Modeling & Simulation • Magnetic Bearings • Rapid Prototyping • System Integration • Aerodynamic Analysis • Engineering Visualization
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Andrews’ Space Development Experience Reusable Booster System
2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011
NASA COTS (RpK) NASA COTS (Orbital) NASA Alternate Access ISS Cargo Vehicle
CubeSat NASA Crew Exploration NASA Crew Exploration NASA High Mass Mars Recovery Vehicle (LM) Entry System
Space / / Space System
NASA Orbital Space Plane (NGC) Human Human
NASA Altair Study NASA Heavy Lift Propulsion Infrastructure Com’l Study NASA Crew Exploration Vehicle (NGC)
NASA Gryphon / ACES USAF Hybrid Launch Vehicle RBS Risk Reduction
DARPA FALCON: Small Launch Veh. Proprietary Launch System
RBS Pathfinder NASA Space Launch Initiative (NGC) DARPA FALCON: CAV DARPA LRTCS
Cost Launch Cost DARPA Arclight
Responsive Low Responsive DARPA ACES
AFRL Tactical Satellite Simulator NASA Small Tug Small Agile Tactical Spacecraft Acquisition of Automated Control
Small Environments (ACE) NPGS Satellite Simulator
Spacecraft Prime Subcontract
Andrews has a highly educated work force capable of executing a wide range of contracts, and top-tier engineering facilities to meet current and future needs
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Andrews Past RBS Studies
Reusable Booster System • Andrews Space has experience with reusable and expendable booster concepts through previous and current efforts – (1999-2002) NASA Space Launch Initiative (SLI) – (2003-2004) DARPA Falcon Small Launch Vehicle – (2005 -2006) USAF Hybrid Launch Vehicle – (2010-2011) NASA Heavy Lift and Propulsion Technology Study – (2010-2011) RBS Risk Reduction Studies – (2011–2012) RBS Pathfinder Phase I
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Why Reusability in a Launch System?
Reusable Booster System • Can provide lower cost per launch Reusability Cost Savings (Example model)
(up to 50% savings) Operations Cost
Other Hardware Cost • Recurring savings can outweigh Main Engine Cost added development costs Development Cost
• Represents a logical step forward in launch technology
Recurring
• Environmental benefits of hardware Cost Cycle
- Cost
re-use Life
• Higher reliability with potential engine-out capability
ExpendableExpendable Booster ReusableReusable Booster
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Reusable versus Expendable Trade Factors
Reusable Booster System Several factors need to be considered when comparing reusable and expendable boosters.
Reusable Booster Expendable Booster Higher Development Costs, Lower Development Costs, Cost Smaller Recurring Costs Higher Recurring Costs Technology development risks Systems using current Risk can impact schedule and cost technologies have lower risk Added booster maintenance can Mature operations based on Operability be offset by improved health significant launch experience management technology Higher booster inert mass Can be more mass-efficient with Performance requires additional thrust and lighter-weight systems increased size High Flight Rate Required to Lower development cost not as Flight Rate Amortize Development Costs sensitive to flight rate
Development cost, recurring cost savings, and flight rate have the highest impact on overall reusable system viability.
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What is the Best Place to Apply Reusability?
Reusable Booster System
A reusable booster is more cost-effective and risk-averse than a reusable upper stage
Booster Upper Stage Optimal LOX/RP has smaller Optimal LOX/LH2 has larger Rocket Systems tanks (higher density / ISP ratio) tanks (lower density / ISP ratio) Optimized for subsonic glide and Design compromises for wide Aerosurfaces landing range of flight conditions Power Systems Duration: 15-20 minutes Duration: 90 minutes to days
Adverse Brief exposure to near vacuum; Extended exposure to space; Environments Heating during ascent Re-entry heating 10x worse Mass growth has low (>10:1) Mass growth has 1:1 impact on Performance Risk impact on payload performance payload performance
Lower Cost & Risk Added Cost & Risk
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Current Andrews Vision Reusable Booster Architecture
Reusable Booster System RBS Architecture Addresses a Wide Range of DoD Payloads
60m
50m
40m
30m
20m
10m
512S 510L 511S 520L 521L Med. LEO & Small LEO; Medium GTO Heavy LEO & Heavy GTO & Mission(s) Polar; Med. Small Polar & High-energy Heavy Polar High-energy ISS; GPS
Liftoff Mass 0.784 M lbm 1.11M lbm 1.13M lbm 1.8 - 1.9M lbm 1.77M lbm P/L Margin 48% 9% - 73% 67% 2% 6%
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RBS Technology Risks – Booster Design
Reusable Booster System • High performance reusable propulsion (Hydrocarbon Boost engine) – Engines are a large cost driver and engine performance determines system size – We know how to make highly reliable, reusable hydrocarbon-fueled jet engines and high performance, but limited-use hydrocarbon-fueled rocket engines – Building highly reliable, reusable, hydrocarbon-fueled rocket engines is possible, but there are risks in meeting performance, weight, or cost goals
• Autonomous Guidance, Navigation & Control – Allows the booster to compute its own trajectory for at least some portions of flight in order to respond to flight conditions and to minimize on-board consumables • Uses flight sensor data and navigation equipment to compute current state • Controls engine and aerosurface effectors to control flight within the allowed flight parameters – Major risks include potential overruns in software development cost and schedule, as well as difficulty in control systems integration
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RBS Technology Risks – Operations (1 of 2)
Reusable Booster System Integrated System Health Management (ISHM) • Goal is to reduce vehicle maintenance time and expense between flights to ascertain equipment readiness and/or state-of-health • Similar to state-of-the-art systems on commercial and military aircraft • Features – Built-in-Test functionality – Sensors to gather data throughout flight – Software to process data and identify anomalies – Human interfaces to relay data to maintenance & operations personnel • Risks include sensor and software development uncertainty, potential creep of requirement scope (want more functionality), and vehicle integration uncertainty
Low maintenance airframes and subsystems • Designing low maintenance airframes and subsystems reduces the cost spent on vehicle upkeep and reduces the time a vehicle spends in a maintenance bay – Line Replaceable Units (LRU) to allow quick replacement of equipment – Temperature sensitive coatings to allow visual inspection – “Green” propellants and fluids to reduce safety issues – Rechargeable battery-powered subsystems to remove complexity of fueled systems • Risks include potential increases in development cost and schedule due to inconclusive technology testing and difficulties in vehicle integration
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RBS Technology Risks – Operations (2 of 2)
Reusable Booster System Automation to reduce operations costs • Designing for automation enforces levels of standardization, interchangeability, simplicity, and robustness that ultimately drive down operations costs and drive up system reliability (think Henry Ford) – Automated integration processes – Automated pad processes • Potential risks include the difficulty of overcoming the status quo to improve operational efficiency, the possibility of workforce reductions or changes, the impact to schedule and cost of infrastructure modifications, and the added cost of training for new operational methods and tools
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Risk Mitigation Strategies
Reusable Booster System • Focused technology programs (i.e. ISHM, materials, propulsion, automation) – Completed in parallel to reduce technological risks and minimize schedule • Ground and flight test programs – Reduce technological and operational risks, and provide demonstrations of actual flight hardware – A sub-scale demonstrator (like Pathfinder) can be developed for a fraction of the cost of a full-scale system • Commercially-developed sub-scale system – Mitigates technological and operational risks, while helping to “sell” a larger, more capable system • Develop new model for regulatory / range processes – Reduce risk of launch scheduling bottlenecks – enhancing an increased flight rate – Range / FAA approvals (maintain public safety) – Licensing processes
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Notional RBS Development Roadmap Reusable Booster System
2010 2020 2030 2040
Technology and demonstration investments now will EELV Program pave the way for an operational RBS
US Government Heavy Lift (SLS)
Advanced Engines
RBS Risk Reduction Reusable Booster RBS Pathfinder
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RBS Development: Range and Recovery Infrastructure
Reusable Booster System • In order to be cost-effective, RBS will require streamlined launch and recovery operations (analogous to airline operations) • Improved range assets are needed for simultaneous tracking of multiple vehicle elements (booster(s) & upper stage after separation) • Landing Facilities closer to launch sites are most effective – Parallel runways or runway extensions would improve operations with multiple boosters – Service aprons would be added to runway for post-landing ops
Booster Service Aprons
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RBS Development: Integration and Launch Infrastructure
Reusable Booster System • Multi-use horizontal integration facility streamlines integration operations − Integrated ground test and checkout − An extension of the multi-use airport concept − Hangar space leased out for RBS storage, processing, and integration • Multi-use, clean pad concept with automated interfaces provides standardization opportunity − Significant departure from today’s custom-built launch pads − Simple launch pad provides basic services with standard interfaces − Each operator brings its own custom launch table
Horizontal Integration Facility Multi-use, Clean Launch Pad
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RBS Development: Workforce/Ground Ops
Reusable Booster System • Viable RBS requires significant reduction in workforce (compared to reusable Space Shuttle) to achieve low operational cost objectives – Some workforce may need to shift from less skilled Shuttle 7800 OpsShuttle Equivalent (launch service technicians) to higher skilled (satellite personnel & other engineering services) jobs as flight rate PROGRAM increases SEGMENT 1600 Improved 20% of VEHICLE Option 1 - Cargo – RBS operations are optimized for steady operations Ops Shuttle SEGMENT Equivalent tempo (flight rate) LAUNCH personnel OPERATIONS • RBS surge capability may require a “standing army” FLIGHT Austere 5% of OPERATIONS 420 • USAF personnel can be trained and stationed to Austere Operations Ops Shuttle Wraps Equivalent address the surge needs personnel • RBS vehicle and infrastructure technologies can reduce Annual Cost Comparison ground processing timelines to meet AF surge requirements – An RBS could be turned around in less than 24-48 hours
RBS 48-hr Maintenance and Integration Workflow
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Impact of Commercial Technology
Reusable Booster System • Applicable RBS Commercial Technology: – Possibility of wrapping a reusable launch system strategy around existing commercially-developed technology (e.g. commercial hydrocarbon engines) – UAV technologies (guidance and control, integrated health management) could be applied to RBS
• Impact of Commercial Market: – Commercial launches represent a significant portion of the overall launch market, as shown in the next chart • The government is buying more and more commercial on-orbit services (e.g. communication, imaging) - should this be extended to launch services? • Additional market potential may enable some form of joint commercial/government development of a reusable booster system – Advancing satellite technology and functional aggregation is leading to smaller spacecraft • Launch capability can be consolidated around an optimal market target (medium–class) • Heavy lift could be done with other government assets like SLS
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Addressable Market – Target Performance Capability Reusable Booster System
Ref: 2011 COMSTAC Forecast
40 all payloads DM
only com'l GTO market - 5 5 ECA 35 only DoD 3SL
only U.S. civil Atlas V Atlas 431
30 VAtlas 551
Ariane
Delta IVHeavy Delta Delta IVM+Delta (5,4)
25 SeaLaunch Extreme impact on design with minimal increase in launch rate
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2 CSG 2 ST
-
Antares Falcon 9 9 Block Falcon 2
15 V Atlas 501
Delta IVMediumDelta Soyuz
10 AverageperPayloadsYear
5 Cumulative Average Payloads perYear Cumulative Payloads Average
0 0 5,000 10,000 15,00015,000 20,00020,000 25,00025,000 30,00030,000 Equivalent GTO Performance Capability (lbm) Best chance for maximum flight rate would require addressing DoD, Civil, and Commercial market sectors
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Summary (1 of 2)
Reusable Booster System • Reusability saves on recurring costs, and may provide an overall life-cycle cost savings
• Booster reusability provides the lowest risk and lowest cost path to reusable launch systems
• Development cost and flight rate are the most important factors when considering a reusable system development – Implementing airline-like operations in range processes will enable higher flight rates – Addressing wider market potential (commercial, civil) increases flight rate
• RBS development and operational risks can be mitigated through selective technology development
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Summary (2 of 2)
Reusable Booster System • RBS infrastructure must focus on simplicity, shared use, and automation to achieve low-cost goals
• Workforce size and skill-set will reflect changes in infrastructure and RBS operation – Automation and standardization will lead to some operations workforce reduction – Some workforce will likely need to transition to higher-skill capability as flight rate increases (needed for automation, ISHM, payload integration skills)
• Commercial development of reusable system technology will happen as market incentives appear. Government implementation of commercially-developed technology may improve the chance of RBS system success.
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Reusable Booster System
Questions?
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