Hypersonic Morphing for
a Cabin Escape System
HYPersonic MOrphing for a Cabin Escape System
Authors: D.Bonetti1, M.Sippel2, G.Gambacciani3, E.Laroche4, M.Kerr1, C.Vallucchi2,
F.Fossati3, F.Sourgen4
Presenter: D.Bonetti (project coordinator)1
1 DEIMOS Space S.L.U., Spain2 DLR, Germany3 Aviospace S.r.l., Italy4 ONERA, France
HYPMOCES Concept
Motivation
Technological Objectives
Project approach
Technological solutions
• System design
• Mission Analysis and GNC
• Aerothermodynamics
• Structure, mechanisms and materials
Impact
Conclusions
Contents
The main goal of HYPMOCES is to investigate and develop the technologies in the area of control, structures, aerothermodynamics, mission and system required to enable the use of morphing in escape systems for hypersonic transport aircrafts.
The HYPMOCES project addresses multiple key technological areas through Concurrent Engineering and a Multi-disciplinary Design Optimization (MDO) process to enable the use of morphing in hypersonic escape systems.
Morphing as the technological solution to balance:
• Constraints for the integration within the mother aircraft (compactness)
• Adaptability to the unpredicted and environment
• Multi-phase nature of the mission
HYPMOCES Concept: Introduction
Future hypersonic transportation will
require a passenger escape system
to reach the desired safety levels
• High energy flight
• Systems reliability
(mainly propulsion)
Cabin Escape Systems have been proposed and implemented with
different levels of success in aeronautics and space.
Motivation
Subsonic Supersonic Military Space
Within EU FP7 project FAST20XX
(coordinated by ESA, participated
by DEIMOS, ONERA, DLR and
others), the CES was addressed
for the SpaceLiner mission.
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Mach Number [-]
SpaceLiner Nominal Trajectory
Full Configuration Ascent
Orbiter Ascent
Orbiter Descent
Hypersonic Regime
Booster
Separation Orbiter
MECO
Motivation: Hypersonic Flight, SpaceLiner CES
orbiter stage
booster stage
passenger cabin
LOX-tank orbiter
LH2-tank orbiter
LOX-tank booster
LH2-tank booster
SpaceLiner (1)
SpaceLiner 2
SpaceLiner 3
SpaceLiner 4
SpaceLiner 5
SpaceLiner 6
SpaceLiner 7
SpaceLiner 7-100
2005
2006
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2011
2012
SpaceLiner (1)
SpaceLiner 2
SpaceLiner 5
(LH2/RP1)
SpaceLiner 4
SpaceLiner 3
SpaceLiner 7
SpaceLiner 6
(Single Stage)
2005
2006
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2010
2011
2012configuration
trade-offs
SpaceLiner (1)
SpaceLiner 2
SpaceLiner 5
(LH2/RP1)
SpaceLiner 4
SpaceLiner 3
SpaceLiner 7
SpaceLiner 6
(Single Stage)
2005
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2012configuration
trade-offs
LOX/RP1
SpaceLiner 5
(LOX/RP1)
Mass: 38 t
Length: 17 m
Morphing is the adaptation of a system to a changing environment
Not necessarily associated with external shape changes
Widely used in aeronautics (subsonic – supersonic), still pioneering in space
and in suborbital flights
Motivation: Morphing
Credits: S.Barbarino
HIAD - NASA
CLIPPER – EU/Russia
SS2 – Virgin Galactic’s
1. System: efficient integration (mass, power, volume)
• Morphing within the escape system
• Escape system within mother aircraft
• System concept
2. Mission and GNC approaches for morphing
• Real time adaptation & reconfiguration of the GNC
– Adaptive Guidance
– LFT/LPV/multimodal control
• Estimation techniques for adaptation / reconfiguration
3. Innovative structural and material solutions:
• Advanced materials, actuators and mechanism and
structural layout
– Ceramic hinges for areas with high thermal load
– Coating protecting lightweight structures from high flux
– Deformable TPS and structures
4. Aerothermodynamics:
• Numerical test bench to support concepts trade-offs
• Micro aerothermodynamics aspects (local gaps, steps)
• Transient effects
• Boundary layer transitions
Technological objectives on multiple areas
Project Manager/
Systems Engineer
Sequential Design (subtask view)
Centralised Design (project view)
Concurrent Engineering Process
“everyone with everyone”
Power
AOCS
Configuration
Thermal
Configuration Power
AOCSThermal
Conventional Design Process
Configuration ThermalPower
iteration
Project Manager/
Systems Engineer
Highly coupled optimization process:
Multi-Disciplinary Design approach
The design from a system level point of view deals with the integration of each subsystem in the most efficient way considering related mass, power required and volume available.
System concept of a hypersonic passengers transportation system
need for a rescue capsule
morphing surfaces within the cabin escape system to enhance vehicle in-flight performance and adaptation to a changing environment.
• Integration of specific hypersonic morphing system solutions adopted (Inflatable / Deployable) within the rescue capsule and integration of the rescue capsule within the SpaceLiner
• Mass, Power and Volume budgets. Mass, CoG and inertia (MCI) properties of the undeployed and deployed morphing system coupling with Flying Qualities, Mission and GNC needs
• Specific subsystems sizing
System design (1/2): Overall concept
CES
MDO
Morphing
Features
Detailed
Design
System design (2/2): Baseline subsystems
FPCS ongoing design activity:
including: EMAs, levers, flap rods, EMACU,
batteries
RCS ongoing design activity:
several thrusters to get roll, pitch and yaw
motion control.
Parachutes altitude-Mach envelope and limiting
factors definition.
Gas Generator (inflatable sidewalls)
Requirements:
• pinfl=120kPa constant within the bags,
• tinfl<2s.
Pyrotechnic ignition: sodium azide+additives,
reaction time 20÷40ms (vol. 45-120l) << tinfl,
reaction temperature 1100÷1350°C,
temperature after expansion 150°C.
MASS BUDGET (propellant+casing+valves including
20% SM): 245 kg each side TOT 490 kg.
Main goal:
Ensure safety in case of abort condition
Trajectory (including morphing) is optimized at multiple abort points along the SL7 trajectory
Optimization is done with the objectives of:
• Improve passengers safety (Extend range flown => simplify rescue operations)
• Improve passengers comfort (Reduce thermo-mechanical loads on the capsule)
• Improve and guarantee appropriate Flying Qualities (Trim, Stability, Control) for GNC
Mission and GNC: reconfiguration (1/2)
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Mach Number [-]
SpaceLiner Nominal Trajectory
Full Configuration Ascent
Orbiter Ascent
Orbiter Descent
Hypersonic Regime
Booster
Separation Orbiter
MECO
SGRA optimization results for MECO Abort Point
Mission and GNC: reconfiguration (2/2)
Main goal:
Ensure robustness against morphing
Selected control approaches: Time-varying parameter impacting the dynamics
Robust control (H∞, ) can
directly tackle the synthesis
problem for uncertain systems
However, time-varying
parameters are regarded as
constant and unknown
Control design
framework
Robust control
LPV control
Information available regarding
the parameters can be used– Time-varying
– Rate bounded/unbounded
The “morphing parameter”,
which is assumed measurable,
can enter directly the synthesis
problem
• Meshing
• Convergence
Aerothermodynamic analyses (1/2)
Hexa box (flaps interaction)
Many refinement sources
(shock, rear flow)
- ~13 millions cells
- 256 procs used
- ATD coeffs accuracy < 0.0002
- 60.000 to 100.000 iterations
Aerothermodynamic analyses (2/2)
Phi < 805 kW/m²
Nose
Phi < 570 kW/m²
Rudders
Phi < 400 kW/m²
IADs
Phi < 600 kW/m²
Phi < 450 kW/m² (In the major part of the flaps)
Flaps
ID Vehicle AoA Elevator AoS Aileron Scope Phase #588 Name
5 Baseline 20 0 -10 0 Sideslip DL2 ID5_DL2
Inflatable sidewalls
Concept view
Structures and materials (1/2)
INFLATABLE SIDEWALLS DESIGN:
Materials:
Nextel: th: 2 mm× 6 layers
Saffil: th: 8 mm × 2 layers
Pyrogel: th: 3 mm× 2 continuous layers
th: 3 mm× 3 discontinuous layers
(T300J carbon fiber: 2 layers)
Total Mass: 1165 kg (each side)
• Complex dynamic simulations
• Complex optimization of bags and
membrane solution (flexible but
robust & stable TPS barrier)
LS-Dyna simulations:
work in progress!Stowed / Deployed configuration
Thermal Analyses
Inflation time: 2s
Flaps and Rudders
Structures and materials (2/2)
Deformation
Analysis
Thermal Analysis
Thermal
Analysis
RUDDERS DESIGN
• Materials: C/C-SiC main bodies with
Saffil insulation at vehicle I/F
• Total mass = 60 kg (each)
• Deployable system: spring & lock
Deformation Analysis
FLAPS DESIGN
• Materials: C/C-SiC main bodies
with local UHTC washers
• Total mass = 86 kg (each)
No hypersonic aircraft is currently in operation. Due to this lack of experience and
because of the complexity of the system and other risk sources inherent to this kind
of system it is deemed essential to provide an escape system in order to bolster the
reduced level of reliability.
Morphing allows increasing the vehicle aerodynamic performance: provides the
system with the necessary robustness to adapt to a changing environment.
This translates into safer flight conditions for passengers in case of emergency
situations. Improved aerodynamics allow for:
• Longer trajectories (easier to reach a safe landing point)
• Lower thermo-mechanical loads (increased passenger comfort)
• Trimmable, stable and controllable flight
The improved safety is considered essential in order to increase acceptance of this
kind of trans-atmospheric transportation by potential customers.
Multiple technological challenges have been approached improving the European
knowledge in designing a complex hypersonic morphing system at multiple levels
(system, GNC & MA, structure and materials, aerothermodynamics).
Impact
Innovative hypersonic inflatable and deployable morphing solutions have been conceived, studied and optimized.
Integration of a mass-volume-power efficient morphing subsystem is extremely challenging.
The problem is multi-disciplinary in nature and requires a highly coupled interaction between conflicting objectives and requirements.
The project is in its last step in which the detailed design of the hypersonic morphing CES will be completed.
A workshop on hypersonic morphing with more detailed insight on the activities performed in the HYPMOCES project is planned on:
26th November 2015
The research leading to these results has received funding from the European Union's Seventh Framework Programme FP7/2007-2013 under grant agreement nº AAT-2012-RTD-341531 entitled “Hypersonic Morphing for a Cabin Escape System (HYPMOCES)”.
Conclusions
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