U.S. patent application number 11/955612 was filed with the patent office on 2009-05-21 for system for use of external secondary payloads.
This patent application is currently assigned to Kistler Aerospace Corporation. Invention is credited to Gary Lai, George E. Mueller, Thomas C. Taylor.
Application Number | 20090127399 11/955612 |
Document ID | / |
Family ID | 32659304 |
Filed Date | 2009-05-21 |
United States Patent
Application |
20090127399 |
Kind Code |
A1 |
Mueller; George E. ; et
al. |
May 21, 2009 |
SYSTEM FOR USE OF EXTERNAL SECONDARY PAYLOADS
Abstract
An experiment system with six different re-entry experiment
locations for testing high temperature re-entry materials, creating
new thermal protection systems, proving innovative new concepts for
spacecraft exterior surfaces and the incremental development of
next generation aerospace materials. A commercial transportation
system to and from orbit provides a 24-hour return cycle for the
experiments on a surface actually re-entering the earth's
atmosphere. Now using existing doors, hatches and other points on
the reusable launch vehicle's exterior, the actual re-entry
environment is experienced by test specimens with quick turn around
for a wide variety of different re-entry temperatures ranges for
broad testing and development purposes. The reusable launch vehicle
launches, remains in orbit for 24 hours and returns to provide an
actual test environment for the exterior experiment system.
Inventors: |
Mueller; George E.;
(Kirkland, WA) ; Lai; Gary; (Seattle, WA) ;
Taylor; Thomas C.; (Las Cruces, NM) |
Correspondence
Address: |
DAVIS WRIGHT TREMAINE, LLP/Seattle
1201 Third Avenue, Suite 2200
SEATTLE
WA
98101-3045
US
|
Assignee: |
Kistler Aerospace
Corporation
Kirkland
WA
|
Family ID: |
32659304 |
Appl. No.: |
11/955612 |
Filed: |
December 13, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
10698261 |
Oct 31, 2003 |
7354020 |
|
|
11955612 |
|
|
|
|
60424159 |
Nov 6, 2002 |
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Current U.S.
Class: |
244/159.1 ;
244/171.1; 244/171.3; 244/173.1 |
Current CPC
Class: |
B64G 1/62 20130101; B64G
1/14 20130101; B64G 1/58 20130101; B64G 1/105 20130101; B64G 1/641
20130101 |
Class at
Publication: |
244/159.1 ;
244/173.1; 244/171.1; 244/171.3 |
International
Class: |
B64G 1/62 20060101
B64G001/62; B64G 1/00 20060101 B64G001/00; B64G 1/40 20060101
B64G001/40 |
Claims
1. A system for introducing payloads into earth orbit, comprising:
a reusable orbital vehicle capable of being placed in earth orbit,
the orbital vehicle having an outer skin; a thermal protection
system attached to the outer skin of the orbital vehicle to thereby
form an outermost layer of the orbital vehicle, the thermal
protection system being formed by materials capable of withstanding
environmental temperatures associated with re-entry of the orbital
vehicle; an internal payload coupled to an interior portion of the
orbital vehicle; and a first external payload package affixed to
the orbital vehicle at a first attachment position on the outer
surface of the outermost layer of the orbital vehicle wherein the
first external payload package is exposed to the external
atmosphere during launch and re-entry phases of a space mission and
is further exposed to the environment of space while in orbit.
2. The system of claim 1, further comprising a second external
payload package affixed to the orbital vehicle at a second position
on the outermost layer of the orbital vehicle wherein the second
external payload package is exposed to the external atmosphere
during launch and re-entry phases of the space mission and is
further exposed to the environment of space while in orbit.
3. The system of claim 2 wherein the first and second external
payload packages have uniform predetermined dimensions, the first
and second attachment positions being configured to receive and
retain the first and second external payload packages at the first
and second attachment positions.
4. The system of claim 1, further a carrier plate assembly
positioned at the first attachment position to receive and retain
the first external payload package.
5. The system of claim 1, further comprising an access panel on the
orbital vehicle wherein first attachment position is located on the
access panel.
6. The system of claim 5 wherein the access panel on the reusable
orbital vehicle is removable from the orbital vehicle.
7. The system of claim 1, further comprising a carrier plate
configured for attachment at the first attachment position and
further configured for attachment to the first external payload
package wherein the carrier plate is intermediate the outer skin
surface of the orbital vehicle and the first package.
8. The system of claim 1 wherein the orbital vehicle has an
elongated shape with first and second ends with a rocket engine
positioned proximate the second end of the orbital vehicle, the
first attachment position being on the outermost layer of the
orbital vehicle substantially at the first end.
9. The system of claim 1 wherein the orbital vehicle has an
elongated shape with first and second ends with a rocket engine
positioned proximate the second end of the orbital vehicle, the
first attachment position being on the outermost layer of the
orbital vehicle forward of a midpoint between the first end and the
second end.
10. The system of claim 1 wherein the orbital vehicle has an
elongated shape with first and second ends with a rocket engine
positioned proximate the second end of the orbital vehicle, the
first attachment position being on the outermost layer of the
orbital vehicle rearward of a midpoint between the first end and
the second end.
11. The system of claim 1 wherein the orbital vehicle has an
elongated shape with first and second ends with a rocket engine
positioned proximate the second end of the orbital vehicle, the
system further comprising an aft skirt proximate the second end
wherein the first attachment position is on an exterior skin
portion of the aft skirt.
12. The system of claim 1 wherein the orbital vehicle has an
elongated shape with first and second ends with a rocket engine
positioned proximate the second end of the orbital vehicle, the
system further comprising an aft skirt proximate the second end and
a protected attachment position on an interior portion of the aft
skirt.
13. The system of claim 1 wherein the orbital vehicle has an
elongated shape with first and second ends with a rocket engine
positioned proximate the second end of the orbital vehicle, the
system further comprising an aft skirt proximate the second end and
an attachment member mounted to an interior portion of the aft
skirt.
14. The system of claim 1, further comprising a sensor associated
with the first experimental package, the sensor generating sensor
data.
15. The system of claim 14, further comprising a data storage unit
electrically coupled to the orbital vehicle and electrically
coupled to the sensor, the data storage unit receiving and storing
the generated sensor data.
16. The system of claim 15 for use with an avionics data bus on the
orbital vehicle to monitor operation of the orbital vehicle, the
data storage unit being coupled to the avionics data bus on the
orbital vehicle to store data related to the operation of the
orbital vehicle in association with the generated sensor data.
17. The system of claim 14 wherein the first external payload
package comprises a thermal protection system.
18. The system of claim 1, further comprising an initial stage
coupled to the orbital vehicle to boost the orbital vehicle from a
position on earth to a predetermined altitude.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention (Technical Field)
[0002] The present invention relates to transporting external test
experiments to and from orbit on the exterior of a reusable launch
vehicle. More particularly, the present invention relates generally
to external vehicle experiments, integration, transport to orbit,
exposure in orbit, exposure to the external re-entry environment
from orbit including instrumentation and testing apparatus and the
return of various support hardware and experiment sample services
used on reusable space transportation vehicles.
[0003] 2. Description of the Related Art
[0004] Note that the following discussion refers to a number of
publications by author(s) and year of publication, and that due to
recent publication dates certain publications are not to be
considered as prior art vis-a-vis the present invention. Discussion
of such publications herein is given for more complete background
and is not to be construed as an admission that such publications
are prior art for patentability determination purposes.
[0005] The transportation of cargo to space is expensive. The
secondary payload hardware has mass and minimum volume.
Transporting the internal secondary payload hardware to and from
orbit in an affordable manner is a goal consistent with life cycle
costs and efficient logistics operations. The problem is the cost
of the individual operations required to transport cargo to orbit.
The part of the transportation operation can be addressed by the
emerging reusable launch vehicles. Kistler Aerospace's secondary
payload hardware research and development has proposed various
additional aerospace structures and opened a new area of technology
and commercial secondary payload hardware accommodation. Secondary
payload hardware structures are a refined technology within the
aerospace community. Unmanned activities in space are less
expensive than manned activities. The unmanned aerospace reusable
launch vehicle (RLV) can provide the secondary payload hardware
technologies to smooth this process.
[0006] The traditional approach to manifesting of space launch
systems has been hardware intensive, safety driven and long
duration scheduling activities. The emerging commercial
technologies point another way and attempt to be sensitive to
commercial customer's launch on demand requirements.
[0007] Many previous space launch patents in prior art discuss
reusable features, but none talk about external payloads designed
to permit the testing of the materials required. The heating on the
surfaces of the reusable launch vehicle are significant and require
testing to develop a reliable reusable material and the testing
environments for development. A typical simulation procedure
requires several wind and arc jet wind tunnels to simulate, on the
earth's surface, part of the re-entry environment experienced in an
actual orbital re-entry.
[0008] U.S. Pat. No. 4,884,770 to Martin, issued on Dec. 5, 1989,
describes a earth to orbit turbojet vehicle, but no mention of
testing external surfaces on the exterior. U.S. Pat. No. 4,796,839
to Davis, issued on Jan. 10, 1989, describes an earth to orbit
vehicle with recovery aspects, but no mention of testing external
surfaces on the exterior. U.S. Pat. No. 4,265,416 to Jackson of
NASA, issued on May 5, 19819, describes a earth to orbit reusable
vehicles, but no mention of testing external surfaces on the
exterior. U.S. Pat. No. 5,568,901 to Stiennon, issued on Oct. 29,
1996, describes a two stage earth to orbit reusable vehicle, but no
mention of testing external surfaces on the exterior surfaces. Even
U.S. Pat. No. 4,802,639 to Hardy, issued on Dec. 5, 1989, describes
an earth to orbit turbojet vehicle, but no mention of testing
external surfaces on the exterior.
[0009] U.S. Pat. No. 5,133,517 to Ware, issued on Jul. 28, 1992,
uses an access door on the external tank, but fails to associate it
to any exterior tests designed to provide samples for thermal
protection system (TPS) analysis in the patent.
[0010] U.S. Pat. No. 4,650,139 to Taylor, issued on Mar. 17, 1987,
attempts to alter the TPS on a partly reusable space launch
vehicle, but enhance the aerodynamic flow by changing the re-attach
point and injecting fluids into the slip stream, but no mention of
returning sample for analysis or removing samples from the vehicle
after re-entry. U.S. Pat. No. 4,790,499 to Taylor, issued on Dec.
13, 1988, expands the original patent, but fails to return any
external samples.
[0011] The exterior sample return from the external tank (ET) of
the space shuttle has been studied by NASA and their manufacturers
in the 1980's, but the sample return from the ET requires removal
of the samples from the ET after it has been taken to orbit. This
involves altering the space shuttle mission trajectory, the salvage
of the ET in orbit, a space walk by an astronaut for removal of the
TPS samples from the ET, the restowing of the samples aboard a
reusable segment of the vehicle and the proper disposal of the ET,
which involves significant additional effort and expense.
[0012] Project Re-Entry II: Returning samples from Earth orbit at
www.gvsp.usra.edu steps around the issue, but discusses low-cost
sample return missions and has held two workshops, but doesn't
mention using the return capsule and a test article for future
mission for exterior materials or future samples for development by
analysis of re-entry materials. The Ariane vehicle by the European
Space Agency creates an Ariane Re-entry Demonstrator (ARD) testbed
to re-enter from earth orbit, but is separate hardware and appears
to have no exterior re-entry samples in the literature or pictures.
Again it is the microgravity that is the focus of ARD rather than
the phased testing approach with incremental development advances
in materials technology based on systematic analysis of re-entry
sample materials from actual re-entry missions.
[0013] Even the Orbital Science Corporation Pegasus alludes to
leading edge research into thermal protection systems on
www.orbital.com and some of their technical papers and literature
details missions for spaceplanes, but all seem to cost an entire
mission instead of the full instrumentation tests with sample back
for analysis in an incremental development manner. Prior art
uncovered to date is not directly germane to the present
invention.
[0014] The space station attempts to address the exposure of
experiments to the space environment, see Brian Berger's article,
"NASA Aims to Finish Express Pallet As Costs Stiffe Brazil's
Plans," SPACENEWS Aug. 26, 2002, 1 p, Springfield, Va., USA. The
Express Pallet does not address either cycle through the
atmosphere, however. Astrocourier (USA) addresses a similar
commercial market, but also does not offer either cycle through the
atmosphere, however.
[0015] Accordingly, it can be appreciated that there is a great
need for a cost effective, reliable, efficient, and safe hardware
systems using integrated technologies containing subsystems common
with the reduced cost hardware solutions. The present invention
provides this and other advantages, as will be apparent from the
following detailed description and accompanying figures.
SUMMARY OF THE INVENTION
[0016] The techniques described herein comprise, in an exemplary
embodiment, a system for introducing payloads into earth orbit. The
system comprises a reusable orbital vehicle capable of being placed
in earth orbit and having an outer skin surface. The vehicle has
plurality of attachment positions located on the outer skin surface
of the orbital vehicle. The system further comprises a first
experimental package affixed to the orbital vehicle at a first one
of the plurality of attachment positions wherein the first
experimental package is exposed to the external atmosphere during
launch and reentry phases of a space mission and is further exposed
to the environment of space while in orbit.
[0017] In an alternative embodiment, the system may further
comprise a second experimental package affixed to the orbital
vehicle at a second one of the plurality of attachment positions
such that the second experimental package is exposed to the
external atmosphere during launch and reentry phases of the space
mission and is further exposed to the environment of space while in
orbit.
[0018] In one embodiment, the system further comprises an access
panel on the outer skin surface of the reusable orbital vehicle
wherein at least one of the plurality of attachment positions is
located on the access panel. The access panels may be removable
from the reusable orbital vehicle.
[0019] The experimental package may comprise a thermal protection
system. In one embodiment, a carrier plate is configured for
attachment at the first one of the plurality of attachment
positions and further configured for attachment to the first
experimental package wherein the carrier plate is intermediate the
outer skin surface of the orbital vehicle and the first
experimental package. Alternatively, the system may further
comprise a thermal protection system affixed to the orbital vehicle
to form the outer skin surface thereof. The thermal protection
system at least one of the plurality of attachment positions being
configured for attachment to the first experimental package.
[0020] The plurality of attachment positions may be in a variety of
different locations on the orbital vehicle. The orbital vehicle has
an elongated shape with first and second ends and a rocket engine
positioned proximate the second end. The first of the plurality of
attachment positions is on the exterior skin of the orbital vehicle
substantially at the first end. Alternatively, a first of the
plurality of attachment positions may be on the exterior skin of
the orbital vehicle forward of a midpoint between the first and
second end. In yet another alternative embodiment, the first of the
plurality of attachment positions may be on the exterior skin of
the orbital vehicle rearward of a midpoint between the first and
second end. In yet another alternative embodiment, the orbital
vehicle also has an aft skirt proximate the second end wherein a
first of the plurality of attachment positions is on an exterior
skin portion of the aft skirt.
[0021] In yet another alternative embodiment, the orbital vehicle
has an aft skirt and a protected attachment position on an interior
portion of the aft skirt. The system may further comprise an aft
skirt with an attachment member mounted to an interior portion of
the aft skirt. In this embodiment, the attachment member may be
rotatably mounted to the interior portion of the aft skirt.
[0022] A second experimental package may be coupled to the
attachment member and, the system may further comprise a control
system to control movement of the attachment member and thereby
position a second experimental package outside the interior portion
of the aft skirt.
[0023] In yet another embodiment, the system further comprises a
sensor associated with the first experimental package, the sensor
generating sensor data. The system may further comprise an
experiment management unit electrically coupled to the orbital
vehicle and electrically coupled to the sensor wherein the
experiment management unit receives and stores the generated sensor
data. The system may also be used with an avionics data bus on the
orbital vehicle used to monitor operation of the orbital vehicle.
In this embodiment, the experiment management unit is coupled to
the avionics data bus to monitor the operation of the orbital
vehicle and to store data related to the operation of the orbital
vehicle in association with the generated sensor data. The sensor
may be used with the first experimental package wherein the first
experimental package comprises a thermal protection system.
[0024] In yet another embodiment, a system for introducing payloads
into earth orbit comprises a reusable orbital vehicle having an
elongated body portion with first and second ends with a rocket
engine positioned proximate the second end of the orbital vehicle
and an aft skirt coupled to the body portion proximate the second
end and extending circumferentially around the rocket engine. The
system further comprises an attachment member mounted to an
interior portion of the aft skirt and configured to receive an
experiment.
[0025] In one embodiment, the attachment member is rotatably
mounted to the interior portion of the aft skirt. In another
embodiment, the attachment member is movably mounted to the
interior portion of the aft skirt and the system further comprises
a control system to control movement of the attachment member to
move the attachment member and thereby position the experiment
outside the interior portion of the aft skirt.
[0026] In one embodiment, the experiment may be an experimental
control surface. In this embodiment, the control system provides
steering control of the attachment to thereby steer the experiment
while positioned outside the interior portion of the aft skirt. In
this embodiment, the system may also comprise a sensor associated
with the experiment to generate sensor data and a data storage unit
to store the generated sensor data.
[0027] Other objects, advantages and novel features, and further
scope of applicability of the present invention will be set forth
in part in the detailed description to follow, and in part will
become apparent to those skilled in the art upon examination of the
following, or may be learned by practice of the invention. The
objects and advantages of the invention may be realized and
attained by means of the instrumentalities and combinations
particularly pointed out in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] The accompanying drawings, which are incorporated into and
form a part of the specification, illustrate several embodiments of
the present invention and, together with the description, serve to
explain the principles of the invention. The drawings are only for
the purpose of illustrating a preferred embodiment of the invention
and are not to be construed as limiting the invention. In the
drawings:
[0029] FIG. 1 is the exterior secondary payload hardware locations
possible on a reusable launch vehicle (RLV).
[0030] FIG. 2 is a fragmentary cross-section of the RLV of FIG. 1
and an external payload illustrating an example mounting of a
standard exterior secondary payload hardware system.
[0031] FIG. 3 illustrates an example of exterior secondary payload
hardware attachment.
[0032] FIG. 4 is the aft skirt launch vehicle location for the
exterior secondary payload hardware deployed while in flight;
[0033] FIG. 5 illustrates the secondary aft skirt payload hardware
of FIG. 4 in a retracted condition.
[0034] FIG. 6 illustrates the secondary aft skirt payload hardware
of FIG. 4 in a deployed condition.
[0035] FIG. 7 illustrates the exterior secondary payload
environment during a flight of the RLV of FIG. 1.
[0036] FIG. 8 is a functional block diagram of an experiment
management unit to control experiments and record data.
DETAILED DESCRIPTION OF THE INVENTION
[0037] In contrast to high cost current technology, the present
invention uses the emerging technologies to create hardware and
procedures of a commercial nature. These secondary payload hardware
systems and environments that start the process of lowering the
cost of space activities by creating a commercial system using
space for commercial gain and supported by affordable
transportation.
[0038] As will be discussed in detail below, the exterior secondary
payload hardware invention provides support for the exterior
experiments and other experiment accommodation hardware and
eventually integrating/delivering/servicing experiment payloads to
low earth in a cost effective manner and return through the
re-entry environment. The hardware of the invention is a reusable
launch vehicle (RLV) supporting a series of exterior secondary
payloads using hardware solutions to create a commercial service
enterprise providing access to the ascent and re-entry environments
for customers.
[0039] The accommodation of external secondary payload hardware on
the launch vehicles uses various methods to provide a commercial
service to the customer. A primary advantage of the techniques
described herein is to reduce costs. This advantage includes the
cost effective combination of a reusable launch vehicle, with both
the ascent and re-entry environment, an affordable subsystem
hardware concept for the commercial attachment of external
experiments, the processing of the experiments within the
integration or refurbishment between flights, the use of the
reusable launch vehicle's avionics, power, communications and other
capabilities and other technologies to reduce the costs for
testing.
[0040] The exterior secondary payload hardware on a reusable launch
vehicle advantageously provides an opportunity for commonality with
existing subsystems already used on the launch vehicle and/or
secondary payload hardware providing cost effective common
subsystems through commonality in design, procurement, testing and
secondary payload hardware attachment.
[0041] The common ground handling techniques, launch on demand
manifesting, technical maintenance, financing and ownership of the
exterior secondary payload hardware, launch vehicle, and payloads
all serve to reduce costs and increase efficiency to the point
where commercialization is feasible.
[0042] Another advantage of the secondary payload hardware is an
integrated design, flexible enough to be capable of accommodating,
on an RLV, a number of different payloads from numerous
organizations with varying requirements, different weights,
different processing requirements, and varying financial needs. The
RLV provides its vehicle capabilities as a testbed for the full
cycle to and from orbit and ground services supporting the exterior
secondary payload hardware payloads in orbit.
[0043] Within structured safety and aerodynamic limits, the
invention includes the various exterior payloads with different
shapes that can be attached to the exterior surface using adaptable
structural interfaces. As will be described in greater detail
below, the exterior secondary payload hardware placed in different
locations on the host launch vehicle with the flexibility, common
subsystems, multiple attachment locations and launch on demand
capabilities of the exterior secondary payload hardware and RLV
combination.
[0044] The exterior secondary payload hardware can be configured in
various sized packages and placed as different sizes in both high
and low heating areas on the host launch vehicle. This second stage
of the RLV is cost effective, because it combines the advantages of
a reusable launch vehicle including the ability to examine the
materials used that is not available with expendable vehicles.
[0045] Another feature described herein includes the stowage of an
experiment within the aft flare volume of the launch vehicle out of
the slip stream. The mounting apparatus has a rotating arm to
introduce this arm tip into the slip stream during the re-entry
phase of the re-entry trajectory.
[0046] In a nominal mission, the exterior secondary payload
hardware is mated with the customer's experiment. The launch
vehicle powers the payload on the full transportation cycle. The
current experimental timeline includes the full ascent exposure, 22
hours of the space environment in orbit and the re-entry
environment to full landing.
[0047] The exterior secondary payload hardware relates to
introducing a full service all in one testing environment, which
can only be simulated on the Earth with a series of wind and arc
jet tunnels to an existing customer base. The new interfaces and
support structure technologies, reusable launch vehicle (RLV)
technology and its use in the space environment of orbit offers a
new avenue of testing that makes many expensive alternatives nearly
obsolete. The present invention provides a more cost-effective
integration, ascent transportation to orbit, 22 hour exposure in
orbit and return through the re-entry environment. The customer
system is capable of placing test samples and experiments into
orbits beyond the capability of sounding rockets, sub-orbital air
launch systems, arc jet/wind tunnels and other current development
methods.
[0048] One example of a fully reusable launch vehicle is the
Kistler Aerospace Reusable Launch Vehicle called the K-1. The
present description illustrates the operation of the invention on
the K-1 reusable launch vehicle. However, the present invention
relates generally to the access to space ascent and re-entry
environments plus hardware innovation and testing locations with
supporting repeatable transportation cycles or missions, the
transfer and attachment of payloads to a variety of space
transportation vehicles for the research, testing and the exposure
of experiments in orbital re-entry environments including the
return of experiment samples to earth for analysis and profit.
[0049] The present invention hardware is capable of providing more
than just the transportation service to orbit like all other
expendable launch vehicles. The experiments, when carried to orbit
and during re-entry from orbit, provide the services such as power,
data recording, sensors, communications and different structural
attachments using the existing Development Flight Instrumentation
(DFI) System on the launch vehicle.
[0050] The development of thermal protection systems (TPS) for
space launch vehicles requires a phased testing and development
process of trial and error on various systems and materials that
are tested and documented afterward. An expendable launch vehicle
limits the analysis afterward, because the hardware and the
exterior samples including the entire stage or vehicle are
discarded in the launch process.
[0051] The K-1 is a reusable launch vehicle and offers the
advantage of exposing the external experiments to the entire
transportation cycle envelope and the opportunity to examine the
experiment samples afterward. To obtain similar conditions from
Mach zero to Mach 25, atmospheric pressures from 14.7 psi to zero
and the thermal environments involved; required previous
researchers and manufacturers to use a series of different wind
tunnel and arc jet tunnels to attempt to duplicate the ascent,
orbital and re-entry environments. This was time consuming,
expensive, labor intensive and less effective than the present
invention.
Experiment Accommodations
[0052] Ordinary expendable launch and re-entry vehicles have a
variety of different environments on the exterior of the vehicle,
but it generally requires two vehicles, one for launch and one for
re-entry to provide the full testing environment. The reusable
launch vehicle can provide the same environment on one reusable
vehicle and repeat the identical experiment in both directions
again on the next mission using a new test experiment.
[0053] The example K-1 vehicle can accommodate three basically
different environment locations with different types of experiments
in both directions of travel on the same vehicle. This is the
subject of this patent application. Externally mounted experiments
are mounted on fail-safe test panels and would include advanced
materials and TPS experiments. Internally mounted experiment
support hardware to support the exterior experiment is accommodated
inside the reusable launch vehicle in a variety of locations on the
vehicle. The third type of experiment is the replacement of an
existing K-1 subsystem or component with one using advanced
technology.
Externally Mounted Experiment Accommodations
[0054] The RLV can place experiments on the outside of the vehicle
to demonstrate the operation of thermal protection systems and
other exterior technologies in an actual launch, orbital, and
reentry environment. While the space shuttle has a full
transportation range of complete ascent and re-entry cycles on the
same vehicle, it does not have the provisions for exterior test
locations or the support hardware to support the testing or the
provisions for supporting the experiments with power,
communications and other services during the experiment phase. The
reusable launch vehicle described herein provides exterior
experiment locations in both directions.
[0055] The Kistler K-1 reusable launch vehicle (RLV) is one example
of such a reusable launch vehicle. The K-1 RLV comprises a booster
stage or launch assist platform (LAP) 58 (see FIG. 7) and an
orbital vehicle (OV) 20 (see FIG. 1). Exterior experiments are
mounted in Kistler supplied hardware of various sizes for use in
various locations. The Kistler-supplied Experiment Containment
hardware can also be used for government and commercial
experiments. Experiments can be placed at locations on the OV nose,
OV Mid-Body, and OV Aft Flare within regions of two different types
of existing thermal protection system (TPS) on the Kistler vehicle.
The repeatable experiments are designed to provide a standard
mechanical and electrical interface for a wide variety of
experiments.
[0056] Reference is now made to FIG. 1, which illustrates an
exemplary embodiment of the invention. FIG. 1 is a side view of
exterior secondary payload hardware locations offering the full
range of re-entry heating environments on reusable orbital vehicle
(OV) 20, which may typically be the second stage of a two-stage
launch vehicle. The initial booster stage, sometimes referred to as
a launch assist platform (LAP), is shown diagrammatically as the
LAP 58 in FIG. 7.
[0057] The OV 22 includes a number of suitable locations where
external payloads may be attached. FIG. 1 illustrates six possible
mounting locations for external payloads on the OV 22 ranging from
a nose 22 location in a high heat area with surrounding thermal
protection system tile to a less severe locations including one low
heat aft skirt 24 location.
[0058] FIG. 1 illustrates an exterior nose experiment footprint 26
(identified as experiment number 1 footprint) at the forward end of
the OV 22 at the opposite end from a launch vehicle engine 28.
Exterior experiment number 2 footprint 30 and exterior experiment
number 3 footprint 32 are approximately 12 feet aft of the nose 22
and use carrier plate 46 footprint experiment hardware. Details of
the carrier plate 46 are provided below.
[0059] Exterior experiment number 4 footprint 34 is at midbody
region of the OV 20 and also uses carrier plate 46 footprint
experiment hardware. Exterior experiment number 5 footprint 36 is
on aft skirt 24 location and includes a tile substitution
experiment location. Exterior experiment number 6 footprint 38 uses
carrier plate 46 footprint experiment hardware and is on aft flare
skirt 24 location.
[0060] The experiments on the K-1 RLV are located in areas where
additional TPS material is located to protect the K-1 RLV from
damage if an experiment breaks or fails. At each of the external
mounting locations, backup insulation, in the form of bordering
blankets and an ablator, is bonded to the K-1 structure to maintain
thermal integrity of the host vehicle (i.e., the OV 20). In
addition to the use of additional thermal material to protect the
OV 20, the experiment footprints may be conveniently located at
hatchways, doors or access panels 39. If a customer experiment
fails, damage would be limited to the access panel 39. The access
panel 39 is removable and can thus be readily replaced if
damaged.
[0061] The mounting footprints described above experience a range
of different heat loads. For the high heat exposure, experiments
can be mounted at experiment number 1 footprint 26 and experiment
number 5 footprint 36. The experimenter will either bond their tile
onto the carrier plate 46, which is then mechanically fastened to
the K-1. Alternatively, the carrier plate can be bonded directly to
the OV 20.
[0062] The footprint of each experiment depends on the mounting
location and the specific reusable launch vehicle. To provide the
necessary thermal protection, the height of each experiment is
generally limited to the TPS Outer Mold Line (OML), which is
approximately 2.0 inches. The OML outline is shown in FIG. 2 by the
cross-section of the TPS 40 of the OV 20.
[0063] For safety reasons, the RLV has certain limitations, such as
no experiments at the experiment number 1 footprint can exceed the
local TPS thickness. The experiment thickness can possibly exceed
the OML by more than 2 inches at experiment number 2-6 footprints
30-38, but will require additional aerodynamic analysis and
verification. The OV 22 can provide data recording to sensors
mounted on or around the experiment, such as thermocouples and
strain gauges, using its existing DFI system and passing insulated
wire through the vehicle structure, ablator, and carrier plate. The
DFI system monitors numerous parameters of the LAP 58 and the OV 20
using conventional technology. Data related to the operation of the
OV 20 is made available on a standard 1553 B data bus. The various
experiments can make use of this system data by monitoring the 1553
B data bus. As will be described in greater detail below,
operational parameters that may be related to an experiment may be
monitored and stored for further analysis by a customer/owner of
the experiment. Details of the DFI system are also provided
below.
[0064] Using the K-1 RLV as an example, the footprint for each
experiment depends on the specific mounting location. Table 1 below
provides example sizes for the experimental footprints 1-6.
TABLE-US-00001 TABLE 1 Passive Experiment Footprint Dimensions
Footprint # Location Type A (in.) B (in.) 1 Nosecap Tile Sub- 9.00
.times. 9.00 9.16 .times. 9.16 stitution 2 Payload Carrier Plate
7.50 .times. 4.25 10.50 .times. 7.25 Module 3 Payload Carrier Plate
7.50 .times. 4.25 10.50 .times. 7.25 Module 4 Mid Body Carrier
Plate 24.00 .times. 24.00 27.00 .times. 27.00 5 Aft Flare Tile Sub-
9.00 .times. 9.00 9.16 .times. 9.16 stitution 6 Aft Flare Carrier
Plate 6.00 .times. 14.00 9.00 .times. 17.00
[0065] In addition, the experiments must meet certain mass
limitations, which are also dependent on the specific RLV and the
specific mounting location. Again, using the K-1 RLV as the
example, Table 2 provides maximum mass values (in pound-mass units)
for each of the exterior experiment footprints 1-6:
TABLE-US-00002 TABLE 2 Passive Experiment Maximum Mass Footprint #
Mass (lbm) 1 12.0 2 5.0 3 5.0 4 20.0 5 12.0 6 12.0
[0066] FIG. 2 is a cross section depicting an example of a customer
thermal protection system (TPS) experiment 42 and thermal
protection system 40 on the OV 20 with an example of carrier plate
46 experiment. The carrier plate 46 provides an optional mounting
method for the customer's TPS experiment 42. The carrier plate is
provided to the customer and the customer's TPS experiment 42 is
bonded to the carrier plate 46. Thus, the customer has the
responsibility of adequately bonding the customer's TPS experiment
42 to the carrier plate 46. The carrier plate 46 has mounting holes
48, which may be best seen in FIG. 3, to permit mounting of the
carrier plate 46 to the OV 20. Thus, the carrier plate 46, with the
customer TPS experiment 42 mounted by the customer, is bolted to
the OV 20 at one of the attachment locations (i.e., the exterior
experiment footprint numbers 1-6). For added protection, an ablator
bonding layer 44 may be inserted beneath the carrier plate 46 to
provide additional protection of the OV 20 in the event of a
failure of the customer's TPS experiment 42. The space surrounding
the customer's TPS experiment 42 and the TPS 40 on the OV 20 is
protected by a border blanket 47. Thus, the customer's TPS
experiment 42 is bonded to the carrier plate 46 and surrounded by
the thermal border blanket 47 such that no gaps are permitted that
might adversely affect the customer's experiment. Those skilled in
the art will appreciate that protection of the customer's TPS
experiment 42 also serves to provide additional thermal protection
for the OV 20.
[0067] FIG. 3 depicts the customer TPS experiment 42 ablator bonded
to carrier plate 46 with multiple bolt holes 48 positioned around
the peripheral edge of the carrier plate plus an instrumentation
wire pass-thru hole 50. The carrier plate 46 illustrated in FIG. 3
may be suitable for mounting in attachment positions such as the
exterior experiment number 2 footprint 30 and the exterior
experiment number 3 footprint 32. Those skilled in the art will
recognize that the shape of the carrier plate 46 and the position
of the bolt holes 48 will vary depending on the footprint outline
(see Table 1 above). However, the arrangement of FIG. 3 illustrates
the use of the carrier plate 46 to receive the customer's TPS
experiment 42 and the arrangement for attaching the carrier plate
46 to the OV 20.
[0068] Sensors 43, such as pressure transducers, strain gauges,
thermocouples and the like may be part of the experiment 42. The
sensor 43 has sensor wires 43w which are routed through the
pass-thru hole 50 for connection to electronics, such as a data
recorder, within the OV 20. As will be described in greater detail
below, an experiment management unit (EMU) 100 (see FIG. 8) has
data processing capabilities to monitor and record data from the
experiment 42. Connections between the data sensors and the EMU 100
are provided by the sensor wires 43w via the pass-thru hole 50.
[0069] FIG. 4 depicts the OV 20 with aft flare skirt 24 region
containing exterior experiment number 5 footprint 36 and exterior
experiment number 6 footprint 38. Exterior experiment number 5
footprint 36 located on a lower region of the aft flare skirt 24
bottom and is thus in a high heat region on the bottom of the OV
20. Due to the high temperatures expected in the attachment area of
the exterior experiment number 5 footprint 36, the customer's TPS
experiment 42 may be directly bonded to the TPS 40 of the aft flare
skirt 24. In applications in this region, the carrier plate 46 (see
FIG. 3) may be eliminated. Border blanket 47 with through holes
(see FIG. 2) can be used around tile substitution customer's TPS
experiment 42 to provide additional thermal protection for the OV
20. Further up on the side of the OV 20 aft flare skirt 24 is a
lower heat area and the location of exterior experiment number 6
footprint 38. A lower expected temperature range associated with
the exterior experiment number 6 footprint 38 permits the use of
the carrier plate 46 for ease in mounting the customer's TPS
experiment 42. The carrier plate arrangement, such as illustrated
in FIG. 3, may be readily adapted for use at the exterior
experiment number 6 footprint 38.
[0070] Also located inside aft flare skirt 24 is an installable
base unit 52 anchoring a deployment arm 54. The deployment arm 54
comprises a base portion 54b, an intermediate portion 54i and a
terminal portion 54t. The deployment arm base portion 54b is
moveably coupled to the base unit 52. The deployment arm base
portion 54b can rotate on an axis of rotation 53 to permit the
deployment arm terminal portion 54t to move into the slip stream
surrounding the OV 20 as it moves in environments with some
atmosphere at high speed. The deployment arm terminal portion 54t
is moveably coupled to the deployment arm intermediate portion 54i
and is capable of rotation in along three different and
substantially orthogonal axes. As illustrated in FIG. 4, the
deployment arm terminal portion 54t can rotate about an axis of
rotation 55, an axis of rotation 57 and an axis of rotation 59.
[0071] The movement of the deployment arm 54 may be electrically
controlled by motors, gears, pulleys and the like. Alternatively,
the deployment arm 54 may be hydraulically controlled. The EMU 100
(see FIG. 8) provides the necessary signals to control movement of
the deployment arm 54.
[0072] The deployment arm 54 is particularly useful for testing
leading edges and control surfaces of space craft and the
associated TPS used thereon. When the deployment arm 54 is
activated and moved into the slipstream, the high speed creates
friction and heat on leading edge TPS experiment 56 and acts
through controllable rotation of the deployment arm 54 as a method
of diverting the slip stream for purposes of steering reusable
orbital vehicle 20. Those skilled in the art will appreciate that
the term "leading edge" refers to the edge of a wing or other
re-entering object. The leading edge encounters significant heating
and is generally the most difficult area of a space craft to test
under simulated conditions. The present invention advantageously
provides a technique for testing leading edge experiments under
actual operating conditions. The leading edge TPS experiment 56 my
be bolted or pinned to the deployment arm terminal portion 54t.
Alternatively, the leading edge TPS experiment 56 may be slipped on
in a shoe arrangement. In yet another alternative embodiment, the
leading edge TPS experiment 56 may be coupled to the deployment arm
54 all the way back inside the aft flare skirt 24 so that the
actual connection is inside the protected volume and not in the
slipstream itself.
[0073] The leading edge TPS experiment 56 may be used to test
steering elements of a space craft. Steering elements, such as
ailerons on a wing or tail rudder steering elements, which are used
to steer a re-entering space craft may be tested as the leading
edge TPS experiment 56. In yet another alternative embodiment, the
leading edge TPS experiment 56 may be used as a steering element
itself. Some theorists have suggested that a single "foot" dangling
behind a re-entering space vehicle in the slipstream can be
mechanically turned to function like a canoe paddle and thus divert
the vehicle back and forth to permit the "S" turns used by the
space shuttle to dissipate the energy of reentry. The leading edge
TPS experiment 56 may be repositioned using the mechanical,
electrical or hydraulic steering subsystem to demonstrate the
efficacy of a single dangling foot used to control S turns.
[0074] Such an approach to experimental design points out another
advantage of the reusable system of the present invention. A space
craft designer can test the testing steering elements on a craft,
such as the OV 20 for several million dollars rather than risking
several billion dollars on a new vehicle with no prior testing of
such steering elements. Utilization of the deployment arm 54 on the
OV 20 allows testing under actual conditions prior to the
commitment of billions of dollars to the development of a new
craft.
[0075] Those skilled in the art will appreciate that use of the
leading edge TPS experiment 56 may alter the steering of the OV 20
in actual operation. Accordingly, the experimental protocol must
take into account the effects of the experiment on the actual
operation of the OV 20. Furthermore, the OV 20 may use the steering
element for non-experimental purposes to control re-entry, as
described above.
[0076] FIG. 5 depicts aft flare skirt 24 region with one retracted
position for deployment unit 52 with one retracted position for
deployment arm 54 capable of rotating into the slip stream
surrounding the OV 20 as it moves in environments with some
atmosphere at high speed. This high speed creates friction and heat
on leading edge TPS experiment 56 for testing and other
purposes.
[0077] FIG. 6 depicts aft flare skirt 24 region for deployment unit
52 with one deployed position for deployment arm 54 capable of
rotating into the slip stream surrounding the OV 20 as it moves in
environments with some atmosphere at high speed. This high speed
creates friction and heat on leading edge TPS experiment 56 for
testing and other purposes. Ground level after landing 92 is far
enough to allow protecting of leading edge TPS experiment 56 for
testing and reuse purposes.
[0078] FIG. 7 depicts the OV 20 launch and re-entry environments
from launch to reuse. The OV 20 launches with the assistance of
launch assist platform 58 and is part of a complete transportation
cycle from launch site landing 80 with experiment recovery 81 to
next launch site landing 80 at ground level after landing 92.
[0079] Carrier plate type customer's TPS experiment 42 and/or tile
substitution type customer's TPS experiment 42 are attached to the
OV 20 and carried with the LAP 58 from near landing area 80 upwards
toward orbit. As the OV 20 moves along an ascent trajectory 88, it
experiences some heating and some re-entry heating and other
environments after stage separation 84 at approximately Mach 4.4 at
approximately 135,000 feet altitude.
[0080] Stage separation occurs at a point 84 along an ascent
trajectory 88. At stage separation 84, the OV 20 separates from the
LAP 58. Following stage separation 84, the LAP 58 changes direction
180 degrees. The center engine on the LAP 58 relights and propels
the nearly empty 1st stage back toward landing 80 area for recovery
and reuse. The LAP 58 experiences some re-entry heating and some
other environments on LAP re-entry phase 86 moving toward landing
80 area.
[0081] Following stage separation 84, the OV 20 continues on the
ascent OV trajectory 88 into orbit and experiences some additional
ascent heating and other environments. The OV 20 reaches orbit,
delivers payload and orbits for approximately 22 hours for the
earth to spin under it and position the OV 20 for re-entry OV
trajectory 82.
[0082] Those skilled in the art will appreciate that the OV 20 may
carry a number of payloads into orbit. These payloads may include
the exterior experiments attached to the OV 20 at the exterior
attachment locations (i.e., the exterior experiment footprint
numbers 1-6 or attached to the deployment arm 54), experiments
contained within the interior of the OV 20 and satellites carried
aboard the OV to be dispensed in orbit. The interior experiments
are discussed in co-pending U.S. patent application Number (not yet
assigned, Express Mail No. ER495032228), entitled COMMERCIAL
EXPERIMENT SYSTEM IN ORBIT, filed on Oct. 9, 2003, which is
assigned to the assignee of the present invention and which is
incorporated herein in its entirety. The use of an active satellite
dispenser to insert one or more satellites into orbit is discussed,
for example, in co-pending U.S. patent application Ser. No.
10/132,083, entitled ACTIVE SATELLITE DISPENSER FOR REUSEABLE
LAUNCH VEHICLE, filed on Apr. 23, 2002, which is assigned to the
assignee of the present invention and which is incorporated herein
in its entirety.
[0083] Moving along re-entry OV trajectory 82, the OV 20 continues
to entry interface 89 and starts pre-entry phase 60 with open loop
bank command at approximately 400,000 feet or 76 miles above the
earth. The OV 20 continues to entry phase 62 with 0.1 gravity
encountered at a point 90 along the re-entry OV trajectory 82.
After continuing along re-entry OV trajectory 82, the OV 20
initiates bank reversal 70 and enters a bank reversal phase 64. The
bank reversal phase 64 refers to a process in which the re-entering
OV 20 performs a series of gentle S turns, such as used by the
shuttle, to dissipate energy and to slow down. The wide gentle
banking in alternating directions (i.e., S turns) allows the OV to
dissipate a significant amount of the energy of re-entry and to
reduce speed. At the end of the bank reversal 72, the OV 20
continues to terminal phase 66 of along the re-entry OV trajectory
82.
[0084] Moving along re-entry OV trajectory 82, the OV 20 deploys a
stabilization chute at a point 74. This starts chute phase 68 and
stabilization chute deployed 74, drogue chute deployed 76 and
finally main chute deployed 78. This chute phase 68 sequence starts
approximately 70,000 feet above the surface.
[0085] The OV 20 continues under parachute to launch site landing
80. Customer's TPS experiment 42 is part of the OV 20 processing
for reuse, which includes experiment recovery 81. Data from sensors
43 is stored on-board the OV 20 and is recovered and returned to
the customer for analysis.
[0086] The OV 20 contains an Experiment Management Unit (EMU) 100,
which provides each experiment with power, if necessary, data
recording for analog sensors, digital data recording, if required,
for example through an RS-422 interface, TTL-compatible digital
discrete control lines, and access to the K-1 1553 B avionics
databus in a shadow or monitor mode.
[0087] FIG. 8 depicts the EMU 100 attached to OV 20. The EMU 100
serves as the interface between various experiments (i.e., the
customer's TPS experiment 42 of FIG. 3) and the OV 20 support
services available from the OV 20 including power, communications,
the 1553 B data bus, control and other services including
transportation.
[0088] Actual avionics flight data from the OV 20 is available via
the 1553 B data bus monitoring 102 through the connection of a
multi-pin vehicle side electrical connector 104 to a mating tray
side connector 106 for the actual flight of the experiment (i.e.,
the customer's TPS experiment 42).
[0089] Communications data from the OV 20 is available via an
RS-422 communications link 108 through the connection of the
vehicle side connector 104 coupled to the sensor wires 43w via an
experiment connector 110 for the actual flight of the
experiment.
[0090] Discrete communications data or separate status information
from the OV 20 is available via discrete commands in 5 standard
wires 112 through the vehicle side connector 104 to the experiment
connector 110 for the actual flight of the experiment.
[0091] Data recording to and from OV 20 is available via data
recorder 114 through analog in 8 standard wires 116 via the vehicle
side connector 104 to the experiment connector 110 for the actual
flight of the experiment.
[0092] Power from the OV 20 is available via power conditioning 118
from an experiment battery 120 in the EMU 100. The experiment
connector 110 on the EMU 100 is shown with experiment support
structure, such as the carrier plate 46 for the actual flight of
the experiment on the OV 20. A power inhibit circuit 128 further
provides control to turn power on and off in 28 volt 2 standard
wire power circuit 130.
[0093] The EMU 100 may include conventional components such as an
analog to digital converter (ADC) 122 to provide digitized signals
124 to the data recorder 114, a digital to analog converter (not
shown) and relay drivers 126 to control the discrete lines, and the
like. The operation of these components is well known in the art
and need not be described herein. The operation of the EMU 100 is
controlled by a control system 132, to provide the necessary timing
for experiments, power control, signal buffering data storage and
the like. The control system 132 may be a microprocessor, digital
signal processor, microcontroller, programmable gate array,
discrete component circuit or the like.
[0094] Well in advance of launch, Kistler K-1 staff delivers each
experimenter an Interface Kit containing the requisite number of
experiment size and thickness details, fasteners, electrical
connectors, and an EMU simulator to verify the electrical
interfaces. The box contains a standard attachment method to mount
experiments. Prior to launch, the experimenters deliver their
experiments mounted on furnished hardware to Kistler; who in turn,
installs the hardware onto the K-1 vehicle. Multiple experiments
from different customers may be placed on the same vehicle, or
experiments may be separated into different locations, depending on
compatibility, temperature or due to other issues. After the
flight, Kistler returns the experiments and data to the
experimenters, and delivers a Post-Flight Report documenting flight
parameters.
[0095] If required, processing areas, office space, and storage
areas at the launch site for the experimenter are available to
support pre-launch checkout and testing. Selected operating
parameters for the OV 20 may be used to assist in designing the
customer experiments. Some of these parameters are provided
below.
[0096] Other parameters have already been discussed or are within
the design skills of a person of ordinary skill in the art
utilizing the disclosure contained herein.
External Experiments
[0097] Kistler's approach to externally mounted experiments is to
replace existing K-1 hardware (access panels, doors, tile, or
blanket parts) with technology experiments on fail-safe test
panels. Panels will be designed with backup insulation and
structure to maintain thermal integrity in the event of an
experiment failure. Data recording will be made available through
the existing developmental flight instrumentation (DFI) system on
the K-1 vehicle.
External Experiment Environments
[0098] Material experiments will be exposed to the ambient air at
Kistler's launch site in Woomera, South Australia.
Thermal Environment
[0099] Heat loads during reentry drive the design of materials and
TPS experiments externally mounted to the orbital vehicle OV vary
with the specific vehicle used. The example K-1 vehicle has
specific predicted heat environment at each identified mounting
location on K-1 Orbital Vehicle locations as shown in table 3
below:
TABLE-US-00003 TABLE 3 Heating Environment in K-1 OV External
Footprints Peak Heating Integrated Rate Heat Load Radiation Eq.
Footprint # (BTU/ft.sup.2/sec) (BTU/ft.sup.2) Temp. (F.) 1 65.0
14,350 3,060 2 9.5 1,830 1,716 3 7.6 1,300 1,598 4 2.2 450 1,050 5
33.0 5,940 2,511 6 12.4 2,435 1,866 NOTE: Radiation equilibrium
temperatures assumes .epsilon. = 0.89 and .delta. = 4.76E-13
Acoustic Environment
[0100] Acoustic loads during reentry drive the design of materials
and TPS experiments externally mounted to the orbital vehicle OV
vary with the specific vehicle used. The example K-1 maximum
predicted noise is 148 to 160 overall sound pressure level (in dB)
at each external mounting location depending on the location,
including the phase of flight the maximum environment occurs. If
Kistler and the experimenter determine acoustic testing is
required, Kistler will provide sound pressure spectrums for
verification testing.
Design Limit Load Factors
[0101] An example K-1 design limit load factor of 35 g encompasses
both predicted static and dynamic loads for externally mounted TPS
experiments. This load factor applies to each axis (one at a
time).
Subsystem Replacement Experiments
[0102] Reusable launch vehicles can substitute a test subsystem for
an existing subsystem on the vehicle. An expendable launch vehicle
can also substitute a test subsystem for an existing working
subsystem, but the test subsystem never comes back for testing and
evaluation. Each type of vehicle could also substitute a test
subsystem and have a back up working subsystem to take over, if the
test subsystem fails. The expendable vehicle would return only one
half of the trips test data and no test system for testing and
evaluation on the ground. The reusable launch vehicle can provide
the full trip cycle of test data. The final category of experiment
open to experimenters is replacement of an existing K-1 subsystem
with one utilizing advanced technology. As an example of this
options is the Space Launch Initiative (SLI) experiments on the K-1
vehicle. Existing interfaces will be maintained between the
experiment and the vehicle. Examples of this type of experiment on
the example K-1 vehicle include: [0103] Replacement of a K-1 TPS
material and joint details with another; [0104] Replacement of one
or more of the K-1's main engines with upgraded engine(s) utilizing
advanced materials, mechanical subsystems, and IVHM; [0105]
Replacement of one of the K-1's batteries with higher energy
density storage devices; [0106] Replacement of one of the K-1's
structural elements, such as propellant tanks, with elements
utilizing advanced materials.
K-1 Development Flight Instrumentation (DFI) System
[0107] Data recording for an example K-1 vehicle is available to
all categories of Space Launch Initiative (SLI) experiments
(externally mounted, internally mounted, and subsystem replacement)
through the K-1's existing DFI system. The DFI system was designed
to provide a modular, tailorable system for measurement of data
required for final verification of the K-1 RLV. Approximately 270
parameters will be measured using the system on the first four K-1
flights. Data measurement instruments in the basic DFI system
include thermocouples, strain gauges, accelerometers, pressure
transducers, temperature gas probes, Resistance Temperature Devices
(RTDs), and microphones.
[0108] The example Kistler K-1 can leave all or part of the
Development Flight Instrumentation (DFI) system in the K-1 vehicle
to support NASA and other customer Add-on Technology Experiment
flights, and can reconfigure and expand the DFI system over 50% to
meet mission needs. The Kistler K-1 baseline DFI system is a
distributed data acquisition system with data nodes located in all
launch assist platform (LAP) and orbiter vehicle (OV) compartments.
There are four OV nodes. Each node is capable of supporting up to
31 channels of analog/digital signal processing. The number of
measurements that a channel can handle is dependent upon the type
of signal being processed. For example: [0109] A thermocouple
channel (card) can process 8 thermocouples [0110] An accelerometer
channel (card) can process 2 accelerometers [0111] A bridge circuit
channel (card) can process 4 bridge circuits. Each node is capable
of streaming 10 Mbps. The baseline DFI system does not send DFI
data to the ground. Real time data is collected and recorded in a
solid-state recorder [one each on the launch assist platform (LAP)
and orbiter vehicle (OV) stages]. Each recorder is capable of
recording four 10 Mbps channels.
[0112] Data from the DFI system is available for use in customer
experiments using the 1553 B data bus in monitoring only mode. For
example, the EMU 100 may monitor data to determine flight status
information. This flight status information can be stored in the
data recorder 114 in association with data from the sensors 43.
Upon completion of the mission, the experiment owner may use the
data for analysis of the experiment. The DFI system data may also
be used by the EMU 100 to trigger certain events. For example, an
experiment involving the deployment arm 54 may require deployment
of the deployment arm at a certain phase of the mission (e.g., the
re-entry phase 62 in FIG. 7). The EMU 100 monitors the 1553 B data
bus to determine the start of the re-entry phase 62 and triggers
the activity of the deployment arm 54.
Experiment Integration Facilities
[0113] Integration facilities required by experiment support crews
vary on a case-by-case basis on other reusable launch vehicles. As
a baseline approach, the example Kistler K-1 will set aside space
in its vehicle processing facility (VPF) for use by the
experiment's support crew as required. Kistler's K-1 example
approach to SLI experiments is to integrate them as part of the
normal maintenance and refurbishment process of the K-1 stages.
[0114] Therefore, placing the experimenter's support facilities in
the Vehicle Processing Facility (VPF) will facilitate experiment
integration into the K-1, which is refurbished and maintained in
the same room. If required, Kistler can segregate the
experimenter's area within the VPF, or provide a separate facility
outside the VPF for use by experimenters. If clean facilities are
required, Kistler can also provide the experiment support crew with
a payload station in its PPF. The availability of the payload
station is subject to coordination with Kistler's payload
customers. The Payload Processing Facility (PPF) is designed to
support satellite processing, test, and integration. The PPF
includes two highbay payload processing work areas, two processing
control rooms, a highbay payload module processing and hazardous
operations area, a master airlock, a support equipment storage
area, and the necessary office and personnel facilities. The
Kistler Mission Control Center is also located in the PPF.
Processing areas in the PPF are Class 100,000 clean facilities.
Ultimately, experiments in the clean facility must be moved into
the VPF for integration into the K-1.
[0115] Other objects, advantages and novel features, and further
scope of applicability will be set forth in part in the detailed
description to follow including drawings taken in conjunction with
the accompanying drawings FIG. 1 through FIG. 7, and in part will
become apparent to those skilled in the art upon examination of the
following, or may be learned by practice of the invention. The
objects and advantages of the invention may be realized and
attained by means of the new testing opportunities process
instrumentation and combinations particularly pointed out in the
appended claims.
[0116] Although the invention has been described in detail with
particular reference to these preferred embodiments, other
embodiments can achieve the same results. Variations and
modifications of the present invention will be obvious to those
skilled in the art and it is intended to cover all such
modifications and equivalents.
INDUSTRIAL APPLICABILITY
[0117] The invention is further illustrated by the following
non-limiting examples.
EXAMPLE 1 PASSIVE EXPERIMENT MOUNTING FOOTPRINTS
[0118] Six footprints are available to mount Passive Experiments on
the outside of the K-1 Orbital Vehicle (OV). These footprints are
attached to the exterior of the vehicle. Kistler's approach for
passive experiments is to replace existing K-1 hardware (access
panels, doors, tile, or blanket parts) with experiments mounted on
Carrier Plates or bonded directly to the K-1 structure.
EXAMPLE 2 PASSIVE STOWAGE WITH ACTIVE RE-ENTRY ENVIRONMENT
EXPOSURE
[0119] Commercial service includes the stowage of an experiment in
the aft flare volume of the launch vehicle out of the re-entry slip
stream and the ability to introduce the movable arm tip upon
command or other control into the re-entry slip stream during the
re-entry phase of the re-entry trajectory.
[0120] The preceding examples can be repeated with similar success
by substituting the generically or specifically described reactants
and/or operating conditions of this invention for those used in the
preceding examples.
[0121] Although the invention has been described in detail with
particular reference to these preferred embodiments, other
embodiments can achieve the same results. Variations and
modifications of the present invention will be obvious to those
skilled in the art and it is intended to cover in the appended
claims all such modifications and equivalents. The entire
disclosures of all references, applications, patents, and
publications cited above are hereby incorporated by reference.
REFERENCE NUMERALS IN DRAWINGS
[0122] 20 reusable orbital vehicle [0123] 22 nose [0124] 24 aft
flare skirt [0125] 26 exterior nose experiment number 1 footprint
[0126] 28 launch vehicle engine [0127] 30 exterior experiment
number 2 footprint [0128] 32 exterior experiment number 3 footprint
[0129] 34 exterior experiment number 4 footprint [0130] 36 exterior
experiment number 5 footprint [0131] 38 exterior experiment number
6 footprint [0132] 39 access panel [0133] 40 thermal protection
system [0134] 42 customer's TPS experiment [0135] 43 sensors [0136]
43w sensor wires [0137] 44 ablator bonded to structure [0138] 46
carrier plate [0139] 47 border blanket with through holes [0140] 48
bolt hole [0141] 50 instrumentation wire pass-thru hole [0142] 52
base unit [0143] 53 axis of rotation [0144] 54 deployment arm
[0145] 55 axis of rotation [0146] 56 leading edge TPS experiment
[0147] 57 axis of rotation [0148] 58 launch assist platform (LAP)
[0149] 59 axis of rotation [0150] 60 pre-entry phase [0151] 62
entry phase [0152] 64 bank reversal phase [0153] 66 terminal phase
[0154] 68 chute phase [0155] 70 initiate bank reversal [0156] 72
bank reversal ends [0157] 74 stabilization chute deployed [0158] 76
drogue chute deployed [0159] 78 main chute deployed [0160] 80
landing [0161] 81 experiment recovery [0162] 82 re-entry OV
trajectory [0163] 84 stage separation [0164] 86 LAP re-entry phase
[0165] 88 ascent OV trajectory [0166] 89 entry interface [0167] 90
0.1 gravity encountered [0168] 92 ground level after landing [0169]
100 experiment management unit (EMU) [0170] 102 1553B data bus
monitoring [0171] 104 vehicle side connector [0172] 106 mating tray
side connector [0173] 108 communications link [0174] 112 standard
wires [0175] 114 data recorder [0176] 116 analog signal wires
[0177] 118 power conditioning [0178] 120 battery [0179] 122 analog
to digital converter (ADC) [0180] 124 digitized signals [0181] 126
relay drivers [0182] 128 power inhibiting circuit [0183] 130 power
circuit [0184] 132 control system
* * * * *
References