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Mission Design
Requirements
First priority is to deliver takeoff mass to aircraft team.
Deliver 5kg item to ISS
24 hour launch lead time
Vehicle must be launched from below or inside carrier
aircraft
Propellants cannot be toxic.
Upper stage must have good orbital insertion accuracy
Vehicle must use off-the-shelf rocket motors
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Desirable Booster
CharacteristicsMinimum takeoff mass
Restart-capable upper stage motor
Simple and reliable upper-stage motor
High Isp upper stage motor
Minimum number of stages
One rocket motor per stage
Minimize G-Forces seen by payload
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Preliminary Booster
CalculationsCreated Excel Spreadsheet
Database of rocket motors from trade studies
Losses neglected:
Gravity
Drag
Calculates:
DV produced by each stage
upper stage structural mass
booster takeoff mass
Max G-Force during launch
Input Variables:
Stage Specifications
Payload Mass
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Booster Calculator
mp1 me1 mp2 me2 mp3 me3 mpl T1 T2 T3 Isp1 Isp2 Isp3
3923 416 1286 98 310 80.20679 40 170000 80000 33300 260 293 330
1st Stage: A TK Orion 50XL
mb01 2230.207 R1 2.816297 2nd Stage: ATK Star 31
m01 6153.207 R2 4.495047 3rd Stage: SpaceX Kestrel 2 (Would like lighter, slightly smaller engine with similar ISP, but sufficient)
mb02 528.2068 R3 7.890381 (Pump fed would reduce weight of upper stage structure, but add compexity)
m02 1814.207 Need very light structure for 2nd stage (85kg including 52kg engine)
mb03 120.2068 Stage 3 G- Force s reduced by throttl ing
m03 430.2068 G-Force at Stage Burnout Total system mass at launch: 6153.207 kg
dv1 2011.145 1 7.770246
dv2 3093.411 2 15.43892
dv3 3832.083 3 28.2388
delta v 8936.64 Adding more liquid fuel reduces max g-forces SpaceX tanks: 3385kg of propellant Propellant mass fraction of 3nd stage
Increasing payload mass reduces max g-forces Empty stage 2: 360kg 0.794451
Stage 1 burnout g-force cl oser to 5.5g Our estimated stage 2 mass: 28.20679 k g (not ideal because motor sl ightly oversized, pressure fed tanks heavy)
Not including engine (SpaceX gets 0.91 with same engine on Falcon 1)
Biggest problem for second stage is lack of small liqui d motors of high Isp in production)
Upcoming LOX-Methane motors hold biggest potential by boosing Isp to 350
Given current limitations, desired change would be to get increased payload requirements, to all ow bigger 1st stage)
Propellant Density (kg/m3) We get lower launch mass with solid upper stage, but need liquid for ISS maneuver due to restart requirements.
Kerosene 806
LOX 1140 Tank pressure: 1.17 Mpa
Oxidizer to fuel ratio for 2nd stage: 2.35 Volume of tanks: Total Tank Mass: 4.875 kg
Helium m3 Helium 1 kg composite
Mass of liquid oxygen: 217.4627 kg LOX 0.190757 m3 LOX 2.718284 kg alloy/composite
Mass of Kerosene: 92.53731 kg Kerosene 0.114811 m3 Kerosene 1.156716 kg composite
Must study anti-slosh baffles for LOX tank, as SpaceX had issue with propellant sloshing with 2nd Falcon I launch. Remaining 3rd stage mass budget
23.33179 kg
Assumes 1 spherical tank
Tank Radius
Helium m
Tank material for LOX-Kerosene: Aluminum-Lithium Al 2135 LOX 0.357109 m
Kerosene 0.30151 m
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Solid Rocket Motorstrade study
Star 26B Thiokol 261 23 272 0.66 64,731 34.6 0.91
Star 26C Thiokol 264 32 272 0.66 63,389 35
Star 30E Thiokol 667 45 291 182,216 35.4 0.88
Star 37FM Thiokol 1147 81 290 0.93 311,041 47.9 0.932
Star 48B Thiokol 2137 126 286 1.25 591,142 66 0.929
Star 48Bs Thiokol 2134 124 286 1.24 578,401 77.109 0.939
Star 48A s Thiokol 2574 144 283 1.24 693,030 77.109 0.942
Star 31 Thiokol 1384 98 294 0.76 380,883 80 0.929
Star 63D Thiokol 3499 248 283 1.6 921,828 84.7 0.929
Star 63F Thiokol 4590 326 297 1.6 1,277,319 104.6 0.929
Perigee O Fourth Ac 4635 496 280 1.4 222.8 0.929
Star 75 Thiokol 8068 565 288 1.91 2,174,539 242.8 0.93
MIHT Russian 6000 1000 220 1.5 245.2
SR-19 Aerojet 7032 795 288 1.33 267.7
Zefiro 9 Fiat-Avio 11100 1000 294 1.9 313
Castor 4B Thiokol 11482 1513 267 1.02 429Algol 3A United Te 14732 2030 259 1.14 464.7 0.868
MIHT-2 Russian 13000 1500 280 1.55 490.3
RSA 3-2 South Afri 10971 1771 284 1.3 519
Castor 4A Thiokol 14851 1723 269 1.02 599.8
LK 1 IAI 13990 1240 272 1.35 774
Pegasus ATK 4350 420 289 1.28 196.4 0.904
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Liquid Rocket Motors
2 separated tanks
Can be stopped or restarted
High specific impulse
3 types
RP-1 widely used for first stages such as Saturn V and Atlas V
- Temperature of Combustion: 3,670 deg K.
- Isp (sl): 300.
- Fuel Density: 0.806 g/cc.
- Fuel Freezing Point: -73 deg C.
- Fuel Boiling Point: 147 deg C
- Oxidiser Density: 1.140 g/cc.
- Oxidiser Freezing Point: -219 deg C.
- Oxidiser Boiling Point: -183 deg C.
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7
Upper Stage Motors
Desired variable thrust, engine restart capability Compared hybrid and liquid rocket motors
Hybrids quickly eliminated due to lower Isp, high structural mass,
and poor commercial availability
For system simplicity/reliability, pressure-fed liquidmotor deemed desirable.
Results of liquid motor trade study led to:
SpaceX Kestrel 2 upper stage rocket motor
Currently used as upper stage for SpaceX Falcon I booster
Pressure-fed LOX-RP1 rocket motor
52kg motor and nozzle
Isp of 330s
Flight-proven design
Currently in serial production
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Rocket Motor DatabaseUpper Stage liquid motors (3rd stage)
Motor Fuel Country Thrust Isp Engine Mass Pressure source Propellant Mass Fraction
HM10 Lox-LH2 France 61.8kN 443 145kg pump Very cryogenic
RD-161P H202-Kerosene Russia 24.5kN 319 105kg pump Non-cryogenic
LR101-11 Lox-Kerosene USA 5.3kN 246 22kg pump Cryogenic oxidizer
Kestrel 2 Lox-Kerosene USA 33.3kN 330 52kg Pressure Cryogenic oxidizer 1.67m nozzle diamet
Lunar ATK Lox-Methane USA 16.7kN 355 30kg Pump Cryogenic propellant and oxidizer In Development for l
XR-5M15 Lox-Methane USA 35.7kN 355 50kg Pump Cryogenic propellant and oxidizer In Development for l
S5.92 N204-UDMH Russia 19.6kN 327 75kg Pump Hypergolic--toxic propellants
S5.98M N204-UDMH Russia 19.6kN 326 95kg Pump Hypergolic--toxic propellants
RD-680 N204-UDMH Ukraine 5.6kN 320 30kg Pump Hypergolic--toxic propellants
XLR-132 N204-MMH USA 16.7kN 328 54kg Pump Hypergolic--toxic propellants Out of production
Upper Stage solid motors (2nd Stage) Empty PropellantStar 17 solid USA 19.6kN 286 7 72 0.881
M-V-4 solid Japan 52.0kN 298 118 1312 0.917483
Star 37FM solid USA 47.9kN 290 81 1066 0.929 Diameter: 0.933m, 1.676m long, 63s burn
Star 30E solid USA 35.4kN 291 45 622 0.932
Star 30BP solid USA 27.0kN 292 38 505 0.931
Orion 38 solid USA 36.0kN 287 108 770 0.876993
Orion 50 solid USA 118.2kN 290 345 3370 0.907133
Star 37 solid USA 43.5kN 260 63 558 0.898551 Diameter 0.66m, 0.84m long
Star 37XFPsolid USA 31.5kN 290 71 884 0.925654 Diameter 0.93m, 1.52m long
1st stage solid motorsATK Orion 50XL USA 170kN 260 416 3923 0.904125 Diameter: 1.28m, 3.11m long, 69.8s burn, +- 5 degree vector control, 33.8
Fiat-Avio Zefiro 9 Italy 300kN 260 1000 10100 0.90991
Nissan M-3B-J Japan 132kN 260 300 3300 0.916667 In development--not yet in production
MIHT-3 Russia 245.2kN 255 1000 5000 0.833333
ATK Star 48B USA 66.0kN 255 126 2011 0.941039 Diameter: 1.245m, TE-M-711, 84s burn
Nissan M-129A Japan 77.5kN 260 360 1840 0.836364
ATK Star 31 USA 80kN 262 98 1286 0.929191 Diameter: 0.762m, TE-M-762, Antares III, 2.9m long, including nozzle, 46s
TX-354-3 USA/Japan 258.9kN 262 695 3729 0.842902
Nissan M34 Japan 294.2kN 264 1000 11000 0.916667
Nissan M33-20-4 USA 268.6kN 247 535 3317 0.861111
ATK Castor 1 USA 237.2kN 260 664 3692 0.847567
X-259 USA 74.0kN 250 300 1100 0.785714
Aerotek M56A-1 USA 228.5kN 260 466 4704 0.909865 Out of production
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Booster Design
3 stage Booster 1st stage: ATK Orion 50XL (Solid)
2nd stage: ATK Star 31 (Solid)
3rd stage: SpaceX Kestrel 2 (LOX-RP1 liquid)
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Booster Design
Interstages
2nd Stage
ATKStar31
1st Stage
ATK
Orion50XL
3rd Stage
SpaceX
Kestrel 2
Fairing
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Stage Specifications
Stage 1 Stage 2 Stage 3
Rocket Motor ATK Orion 50XL ATK Star 31 SpaceX Kestrel 2
Propellant Solid Solid LOX-RP1 Liquid
Empty Mass 416kg 98kg 84kg
Propellant Mass 3923kg 1286kg 350kg
Specific Impulse 260s 293s 330s
Thrust 170kN 80kN 33.3kN
Burn Time 69.8s 46s 34s
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Comparison to Pegasus
AirLaunch PegasusXL
1 stage maneuver Zero-velocity gravity Winged pull-up
Takeoff Mass 6,298kg 23,130kg
Carrier Aircraft C-17 Lockheed L-1011
Aircraft Mounting Internal Cargo Bay External Wing Pylon
Payload to LEO 150kg (1) 443kg
Diameter 1.7m 1.27m
Length 12.5m 17.6mUpper Stage Pressure-fed liquid Solid+HAPS System (2)
(1) Payload for AirLaunch mission is 120kg fuel and 30kg satellite
(2) Monopropellant hydrazine thruster for upper stage trajectory error correction
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Comparison to Pegasus
Pegasus
AirLaunch
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Gravity Turn Simulations:
Used Joe Muellers Matlab code to simulategravity turn
Parameters that can be varied in code:
Flight Path Angle (FPA)
Height at which ignition 3 starts
Mass of Stage 3 Propellant
Launch Flight Path Angle:
87.97 Deg.
Trials System mass Eccentricity Perigee
Altitude
Apogee
Altitude
1 6278 kg 0.00918 240.42 km 363.12 km
2 6293 kg 0.00183 322.42 km 346.96 km
3 6298 kg 0.00093 330.46 km 342.84 km
Targeted ISS
Orbital
elements
0.00053 334 km 341 km
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C-17 carrier aircraft
LV initial launchconditions:
t = 0 seconds
V 0 m/s
H 12 km
FPA 88
Launch Vehicle (LV)
Launch Vehicle (LV) initial launch conditions:
FPA
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Launch trajectory:
Simulations produced the following direct launch trajectory
to reach ISS:Targeted ISS perigee
altitude of 334 km
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3D Orbit of Payload:
Matlab simulation produced the following orbit:
Payloads Low
Earth Orbit
Inclination: 51
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Detailed orbit simulations:
Satellite Tool Kit (STK) orbit simulations:
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STK simulation:
Used STK to simulate orbit ofpayload relative to ISS
Apoapsis and Periapsis visible
Enjoy the excellent video
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