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NASA Space Launch Initiative (NGC) DARPA FALCON: CAV DARPA LRTCS

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NASA Space Launch Initiative (NGC) DARPA FALCON: CAV DARPA LRTCS 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 2 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 3 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 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 4 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 5 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 6 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. 7 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 8 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% 9 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 10 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 11 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 12 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 13 Notional RBS
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