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DLR Reusability Flight Experiment Refex Journal Pre-proof DLR Reusability Flight Experiment ReFEx Waldemar Bauer, Peter Rickmers, Alexander Kallenbach, Sven Stappert, Viola Wartemann, Clemens Hans-Joachim Merrem, René Schwarz, Marco Sagliano, Jan Thimo Grundmann, Andreas Flock, Thomas Thiele, Daniel Kiehn, Andreas Bierig, Jens Windelberg, Eugen Ksenik, Thorben Bruns, Tobias Ruhe, Henning Elsäßer PII: S0094-5765(19)31429-8 DOI: https://doi.org/10.1016/j.actaastro.2019.11.034 Reference: AA 7779 To appear in: Acta Astronautica Received Date: 30 July 2018 Revised Date: 29 July 2019 Accepted Date: 24 November 2019 Please cite this article as: W. Bauer, P. Rickmers, A. Kallenbach, S. Stappert, V. Wartemann, C. Hans- Joachim Merrem, R. Schwarz, M. Sagliano, J.T. Grundmann, A. Flock, T. Thiele, D. Kiehn, A. Bierig, J. Windelberg, E. Ksenik, T. Bruns, T. Ruhe, H. Elsäßer, DLR Reusability Flight Experiment ReFEx, Acta Astronautica, https://doi.org/10.1016/j.actaastro.2019.11.034. This is a PDF file of an article that has undergone enhancements after acceptance, such as the addition of a cover page and metadata, and formatting for readability, but it is not yet the definitive version of record. This version will undergo additional copyediting, typesetting and review before it is published in its final form, but we are providing this version to give early visibility of the article. Please note that, during the production process, errors may be discovered which could affect the content, and all legal disclaimers that apply to the journal pertain. © 2019 Published by Elsevier Ltd on behalf of IAA. DLR Reusability Flight Experiment ReFEx Waldemar Bauer a) , Peter Rickmers a) , Alexander Kallenbach b) , Sven Stappert a) , Viola Wartemann f) , Clemens Hans-Joachim Merrem f) , René Schwarz a) , Marco Sagliano a) , Jan Thimo Grundmann a) , Andreas Flock c) , Thomas Thiele c) , Daniel Kiehn d) , Andreas Bierig d) , Jens Windelberg d) , Eugen Ksenik a) , Thorben Bruns a) , Tobias Ruhe e) , Henning Elsäßer e) a) German Aerospace Center (DLR), Institute of Space Systems, Robert-Hooke-Str. 7, 28359 Bremen, Germany, [email protected], [email protected], [email protected], [email protected], [email protected], [email protected], [email protected], [email protected] b) German Aerospace Center (DLR), Space Operations and Astronaut Training, Mobile Rocket Base, 82234Wessling, Germany, [email protected] c) German Aerospace Center (DLR), Institute of Aerodynamics and Flow Technology, Linder Hoehe, 51147 Cologne, Germany, [email protected], [email protected] d) German Aerospace Center (DLR), Institute of Flight Systems, Lilienthalplatz 7, 38108 Braunschweig, Germany, [email protected] , [email protected] , [email protected] e) German Aerospace Center (DLR), Institute of Structures and Design, Pfaffenwaldring 38-40, 70569 Stuttgart, Germany, [email protected] , [email protected] f) German Aerospace Center (DLR), Institute for Aerodynamics and Flow Technology, Lilienthalplatz 7, 38108 Braunschweig, [email protected], [email protected] Abstract The German Aerospace Center (DLR) is currently developing the Reusability Flight Experiment (ReFEx). The successor of the already performed hypersonic flight experiments SHEFEX I and II shall be launched on a Brazilian VSB-30 sounding rocket in 2022 and shall achieve a re-entry velocity of more than Mach 5. The main goals of the project are the demonstration of a controlled autonomous re-entry flight from hypersonic velocity down to subsonic range and the testing of the key technologies required for future reusable first stage systems . Utilizing Concurrent Engineering (CE) approach the fundamental feasibility of this sophisticated flight experiment has been investigated by the entire ReFEx team. All required systems, including sensors and actuators as well as their interfaces have been defined and different options were assessed regarding matters such as the scientific output, complexity, risk and cost. The current configuration of ReFEx has a re-entry mass of about 400 kg, a length of 2.7 m and a wingspan of 1.1 m. This paper provides a system overview and addresses the Reusable Launch Vehicles (RLV) technologies Guidance, Navigation and Control as well as Flight Instrumentation. Furthermore the mission design (launch & re-entry) and the main challenges regarding the mission realization are addressed. Keywords: (ReFEx, reusable launch vehicle, reusable system, launch vehicle, space transportation) 1. Introduction Vehicle Concepts: the Liquid Fly Back Booster (LFBB, DLR) [1], the Evolved European Reusable Launch vehicles are complex and expensive Space Transport (EVEREST, Airbus, former systems the costs of which cannot be spread over EADS ST) [2], the Skylon (Reaction Engines many missions if the vehicles are expendable. Limited, UK) [3], the Baikal (Khrunichev, Russia) Therefore, worldwide research activities at [4], the sub-orbital Hopper (Airbus, former universities, research institutions and especially Daimler-Chrysler Aerospace) [5] as a finding of industrial companies are ongoing to find solutions the Future European Space Transportation to reduce the cost of launch systems for future Programme (FESTIP, ESA) [6], the Aurora missions. Different concepts and technical (POLARIS Raumflugzeuge, Germany) [7, 8], the products have been developed in the past or are Clipper (EURO-Russian Spaceplane) [9]. still under development e.g.: Flight Experiments & Demonstrators: the of the VTHL concept in the frame of the Беспилотный O рбитальный P акетоплан (to Reusability Flight Experiment (ReFEx) project English: Orbital Plane without Pilot, BOR, ZAGI, [30] which pasted the Preliminary Design Review Russia) [10], the European eXPErimental Re-entry (PDR) in May 2019. The flight demonstration of Test-bed (EXPERT, ESA, manufactured, not ReFEx is planned as well for 2022. Additionally, flown) [11], the European Intermediate the DLR is performing system studies on full-scale eXperimental Vehicle (IXV, ESA) [12], the RLV VTVL and VTHL concepts to assess the HEXAFLY-INT (EU-ESA, flight in 2021) [13], efficiency of reusability regarding e.g. the the Reusable Launch Vehicle Testbed (RLV-TD, operations, the performance, the costs and the ISRO) [14], the Hypersonic International Flight logistics of the launch systems [31], [32]. Research Experimentation (HIFiRE, Australian- U.S) [15], the Sharp Edge Flight Experiment I & II Having access to the technological know-how of (SHEFEX I & II, DLR) [16, 17], the Phoenix both types of vehicles allows the DLR to perform a (German national program) [18], the Space-Rider more appropriate assessment of different (ESA, flight in 2021) [19], the Phantom Express technologies as it is possible today and to support (DARPA, US, flight in 2021) [20]. decisions regarding future launch systems. Operational or Nearly Operational Systems: the To realize the ReFEx project, the DLR uses Space Shuttle (NASA, US, retired) [21], the Buran existing experience from a number of previous (ZAGI, Russia, retired) [22], the Dream Chaser projects. For example, in the frame of the ASTRA (Sierra Nevada Corporation, US, flight in 2020+) study [1] together with German industry and [23], the New Glenn (Blue Origin, US, flight in universities, a large number of numerical 2021), [24], the Falcon 9 [25] and Falcon Heavy investigations as well as dedicated wind tunnel [26] (SpaceX, US). tests were performed. Furthermore, the DLR earned practical experience on national projects, The solutions consider different technologies and such as SHEFEX I and II [17, 33], as well as in operational sequences and could be potentially international cooperation projects, e.g. FOTON utilized for future space transportation as partially [34], EXPRESS [35] and HIFiRE [36–38]. Within or fully reusable launch vehicles. Up to now the those projects, different key technologies required Vertical Take-off and Vertical Landing (VTVL) for Reusable Launch Vehicles (RLV) were already vehicles have been studied by a number of developed and tested (e.g. thermal protection institutions and successfully demonstrated by the system, hybrid canards, navigation system). Falcon 9 [25] and Falcon Heavy [26] vehicles. Furthermore, measurement data was collected und Furthermore, the Vertical Take-off and Horizontal utilized for model validation. The main goals of Landing (VTHL) vehicles were realized in the past the ReFEx project are: e.g. the BOR [10], the Buran [10], the Space Shuttle [27], the RLV-TD [14] or are currently • Perform a controlled flight following a re-entry ongoing e.g.: the Phantom Express [7]. Moreover, trajectory representative for a winged RLV first stage in the velocity range hypersonic down to the Horizontal Take-off and Horizontal Landing subsonic (see Fig 8, RLV corridor) (HTHL) method was demonstrated by the Phoenix • Perform a controlled heading change (capability (subsonic flight and landing) vehicle [28] and is required for returning to the launch site) currently under development in the frame of e.g. • Test of the autonomous Guidance Navigation the Aurora [7, 8] and the Skylon [3] projects. and Control (GNC) system • Perform In Flight Data acquisition using However, the analysis results, the flight data as advanced sensors well as the cost efficiency of different technologies • Recovery of the Re-Entry Segment (see Fig 2 are not sufficiently available which makes right) for Post Flight Analysis (PFA) appropriate assessment of future launch systems To achieve those goals it is necessary to provide difficult.
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