briefing to the national research council’s aeronautics...
TRANSCRIPT
Reusable Booster System
Briefing to the National Research Council’s
Aeronautics and Space Engineering Board
28 March 2012
Reusable Booster System
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Hard
ware
Inte
gra
tio
n
Miniature Active
Guidance Units
Satellite Simulators Ballute Flight
Experiment
Responsive Space
Launch Vehicles
Syste
m D
esig
n
Exp
eri
en
ce
ESPA Class Solar
Electric Vehicle
Tactical Imaging
Nanosat
Kistler K-1 Triplex
Subsystem
Management Unit
Bigelow Genesis II ADCS
– 2 years on orbit with no
faults
Aerojet Sundancer Fault
Tolerant Propulsion
Controller
Flig
ht
Qu
alifi
ed
Av
ion
ics
Responsive
and
Innovative
System
Solutions
Andrews is a Small Agile System Integrator
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.
Reusable Booster System
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Andrews Space Business Areas and Customers
• Systems Engineering
• Design Development & Analysis
• Modeling & Simulation
• Rapid Prototyping
• System Integration
• Aerodynamic Analysis
• Engineering Visualization
• Advanced Thermal / Material Technologies
• Deployable Technologies
• Air Collection & Enrichment System
• Magnetic Bearings
Advanced Technologies Technical Services
• Nanospacecraft
• SHERPA In-space Tug
• Hypersonic Platforms
• Responsive Launch Systems
• SENTRY Nanospacecraft Bus
• Avionics & Electronics
• Spacecraft Reaction Wheels / CMGs
• Spacecraft ADCS sensors
• Satellite Test Beds
• Ground Support Equipment
Integrated Systems Products & Components
Reusable Booster System
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Andrews’ Space Development Experience
2008 2007 2006 2005 2004 2003 2002 2001 2000
Co
m’l
Sp
ac
e /
Hu
man
Infr
as
tru
ctu
re
Res
po
nsiv
e L
ow
Co
st
Lau
nc
h
Sm
all
Sp
ac
ec
raft
Prime Subcontract
2009 2010 2011
NASA Alternate Access ISS Cargo Vehicle
NASA Orbital Space Plane (NGC)
NASA COTS (RpK)
NASA Gryphon / ACES
NASA Space Launch
Initiative (NGC)
DARPA FALCON: Small Launch Veh.
DARPA FALCON: CAV
DARPA ACES
DARPA LRTCS
DARPA Arclight
NASA Small Tug
NASA Crew Exploration NASA Crew Exploration
Vehicle (LM)
NASA Crew Exploration
Vehicle (NGC)
USAF Hybrid Launch Vehicle
Acquisition of
Automated Control
Environments (ACE)
AFRL Tactical Satellite
Simulator
Proprietary Launch System
RBS Risk Reduction
NASA Altair Study
NASA High Mass Mars
Entry System
CubeSat
Recovery
System
Small Agile Tactical Spacecraft
NPGS Satellite Simulator
NASA COTS (Orbital)
NASA Heavy Lift Propulsion
Study
RBS Pathfinder
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
Reusable Booster System
Andrews Past RBS Studies
• 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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Reusable Booster System
Why Reusability in a Launch System?
• Can provide lower cost per launch
(up to 50% savings)
• Recurring savings can outweigh
added development costs
• Represents a logical step forward in
launch technology
• Environmental benefits of hardware
re-use
• Higher reliability with potential
engine-out capability
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Reusability Cost Savings (Example model)
Reusable BoosterExpendable BoosterLi
fe-C
ycle
Co
st
Operations Cost
Other Hardware Cost
Main Engine Cost
Development Cost
Recurring
Cost
Reusable Expendable
Reusable Booster System
Several factors need to be considered when comparing
reusable and expendable boosters.
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Reusable versus Expendable Trade Factors
Reusable Booster Expendable Booster
Cost Higher Development Costs,
Smaller Recurring Costs
Lower Development Costs,
Higher Recurring Costs
Risk Technology development risks
can impact schedule and cost
Systems using current
technologies have lower risk
Operability
Added booster maintenance can
be offset by improved health
management technology
Mature operations based on
significant launch experience
Performance
Higher booster inert mass
requires additional thrust and
increased size
Can be more mass-efficient with
lighter-weight systems
Flight Rate High Flight Rate Required to
Amortize Development Costs
Lower development cost not as
sensitive to flight rate
Development cost, recurring cost savings, and flight rate
have the highest impact on overall reusable system viability.
Reusable Booster System
What is the Best Place to Apply Reusability?
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A reusable booster is more cost-effective and
risk-averse than a reusable upper stage
Booster Upper Stage
Rocket Systems Optimal LOX/RP has smaller
tanks (higher density / ISP ratio)
Optimal LOX/LH2 has larger
tanks (lower density / ISP ratio)
Aerosurfaces Optimized for subsonic glide and
landing
Design compromises for wide
range of flight conditions
Power Systems Duration: 15-20 minutes Duration: 90 minutes to days
Adverse
Environments
Brief exposure to near vacuum;
Heating during ascent
Extended exposure to space;
Re-entry heating 10x worse
Performance Risk Mass growth has low (>10:1)
impact on payload performance
Mass growth has 1:1 impact on
payload performance
Lower Cost & Risk Added Cost & Risk
Reusable Booster System
Current Andrews Vision Reusable Booster Architecture
512S 510L 511S 520L 521L
Mission(s) Small LEO;
Small Polar
Med. LEO &
Polar; Med.
ISS; GPS
Medium GTO
& High-energy
Heavy LEO &
Heavy Polar
Heavy GTO &
High-energy
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%
60m
50m
40m
30m
20m
10m
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RBS Architecture Addresses a Wide Range of DoD Payloads
Reusable Booster System
RBS Technology Risks – Booster Design
• 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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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 (1 of 2)
Reusable Booster System
RBS Technology Risks – Operations (2 of 2)
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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Reusable Booster System
Risk Mitigation Strategies
• 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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Reusable Booster System
Notional RBS Development Roadmap
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2010 2020 2030 2040
EELV Program
Reusable Booster RBS Pathfinder
Technology and
demonstration
investments now will
pave the way for an
operational RBS
Advanced Engines
US Government Heavy Lift (SLS)
RBS Risk Reduction
Reusable Booster System
RBS Development: Range and Recovery Infrastructure
• 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
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Booster
Service Aprons
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
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RBS Development: Integration and Launch Infrastructure
Horizontal Integration Facility Multi-use, Clean Launch Pad
Reusable Booster System
RBS Development: Workforce/Ground Ops
• 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
(launch service technicians) to higher skilled (satellite
& other engineering services) jobs as flight rate
increases
– RBS operations are optimized for steady operations
tempo (flight rate)
• RBS surge capability may require a “standing army”
• USAF personnel can be trained and stationed to
address the surge needs
• RBS vehicle and infrastructure technologies can reduce
ground processing timelines to meet AF surge requirements
– An RBS could be turned around in less than 24-48
hours
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Shuttle
Option 1 - Cargo
Austere Operations
PROGRAM SEGMENT
VEHICLE SEGMENT
LAUNCH
OPERATIONS
FLIGHT OPERATIONS
Wraps
20% of
Shuttle
5% of
Shuttle
7800
Equivalent
personnel
1600
Equivalent
personnel
420
Equivalent
personnel
Shuttle
Ops
Improved
Ops
Austere
Ops
Annual Cost Comparison
RBS 48-hr Maintenance and
Integration Workflow
Reusable Booster System
Impact of Commercial Technology
• 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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Reusable Booster System
0
5
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40
0 5,000 10,000 15,000 20,000 25,000 30,000
Cu
mu
lati
ve A
vera
ge P
aylo
ads
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Equivalent GTO Performance Capability (lbm)
An
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551
Ari
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CA
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eavy
0
5
10
15
20
25
30
35
40
0 5,000 10,000 15,000 20,000 25,000 30,000
Av
era
ge
Pa
ylo
ad
s p
er
Yea
r
Equivalent GTO Performance Capability (lbm)
all payloads
only com'l GTO market
only DoD
only U.S. civil
Addressable Market – Target Performance Capability
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Extreme impact on design with
minimal increase in launch rate
Best chance for maximum flight rate would require
addressing DoD, Civil, and Commercial market sectors
Ref: 2011 COMSTAC Forecast
Reusable Booster System
Summary (1 of 2)
• 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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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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Summary (2 of 2)
Reusable Booster System
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Questions?