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Pegasus XL Development and L-1011 Pegasus Carrier Aircraft

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I I I I I I I I I I I I I I I I I I I PEGASUS<iI XL DEVELOPMENT AND L-1011 PEGASUS CARRIER AIRCRAFT by Marty Mosier' Ed Rutkowski 2 Orbital Sciences Corporation Space Systems Division Dulles, VA Abstract The Pegasus air-launched space booster has established itself as America's standard small launch vehicle. Since its first flight on April 5, 1990 Pegasus has delivered 13 payloads to orbit in the four launches conducted to-date. To improve ca- pability and operational flexibility, the Pegasus XL development program was initiated in late 1991. The Pegasus XL vehicle has increased propellant, improved avionics, and a number of design en- hancements. To increase the Pegasus launch system's flexibility, a Lockheed L-1 011 aircraft has been modified to serve as a carrier aircraft for the vehicle. In addition, the activation of two new Pegasus production facilities is underway at Vandenberg AFB, California and the NASA Wal- lops Flight Facility, Wallops, Virginia. The Pe- gasus XL vehicle, L-1011 carrier aircraft, and Vandenberg production facility will be operational in the fall of 1993. This paper describes the .••• I Figure 1. Pegasus XL and L-1011 Carrier Aircraft. 1993 by Orbital Scienct:'s Corpor.Jtiun. Pllhlislk"d hy the Institule uf AeronautiC'S :and Astron:alllics,lIk'. wilh Pegasus XL vehicle design, capability, develop- ment program, and payload interfaces. The L- 1011 carrier aircraft is described, including its selection process, release mechanism vehicle and payload support capabilities, and certification pro- gram. Pegasus production facilities are described. Background The Pegasus air-launched space booster (Fig- ure 1), which first flew on April 5, 1990, provides a flexible, and cost effective means for delivering satellites into low earth orbit. 1 Four launches have occurred to-date, delivering a total of 13 payloads to orbit. Launches have been conducted from both the Eastern (Kennedy Space Center, Florida) and Western (Vandenberg, California) Ranges. All of the vehicles launched to-date have been integrated using OSC's Vehicle Integration Building located at the NASA Dryden Flight Re-
Transcript
Page 1: Pegasus XL Development and L-1011 Pegasus Carrier Aircraft

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PEGASUS<iI XL DEVELOPMENT AND L-1011

PEGASUS CARRIER AIRCRAFT

by

Marty Mosier' Ed Rutkowski2

Orbital Sciences Corporation Space Systems Division

Dulles, VA

Abstract

The Pegasus air-launched space booster has established itself as America's standard small launch vehicle. Since its first flight on April 5, 1990 Pegasus has delivered 13 payloads to orbit in the four launches conducted to-date. To improve ca­pability and operational flexibility, the Pegasus XL development program was initiated in late 1991. The Pegasus XL vehicle has increased propellant, improved avionics, and a number of design en­hancements. To increase the Pegasus launch system's flexibility, a Lockheed L-1 011 aircraft has been modified to serve as a carrier aircraft for the vehicle. In addition, the activation of two new Pegasus production facilities is underway at Vandenberg AFB, California and the NASA Wal­lops Flight Facility, Wallops, Virginia. The Pe­gasus XL vehicle, L-1011 carrier aircraft, and Vandenberg production facility will be operational in the fall of 1993. This paper describes the

.••• I

Figure 1. Pegasus XL and L-1011 Carrier Aircraft.

(Copyri~hltD 1993 by Orbital Scienct:'s Corpor.Jtiun. Pllhlislk"d hy the AJ(~rican Institule uf AeronautiC'S :and Astron:alllics,lIk'. wilh pt:'rrllis~oll.)

Pegasus XL vehicle design, capability, develop­ment program, and payload interfaces. The L-1011 carrier aircraft is described, including its selection process, release mechanism vehicle and payload support capabilities, and certification pro­gram. Pegasus production facilities are described.

Background

The Pegasus air-launched space booster (Fig­ure 1), which first flew on April 5, 1990, provides a flexible, and cost effective means for delivering satellites into low earth orbit. 1 Four launches have occurred to-date, delivering a total of 13 payloads to orbit. Launches have been conducted from both the Eastern (Kennedy Space Center, Florida) and Western (Vandenberg, California) Ranges. All of the vehicles launched to-date have been integrated using OSC's Vehicle Integration Building located at the NASA Dryden Flight Re-

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search Facility, Edwards AFB, California (NASA DFRF). Three of the launches were conducted off the coast of California within the control of the Western Test Range (WTR). The third mission, conducted in February 1993 forthe Brazilian SCD-1 mission, demonstrated the Pegasus launch system's exceptional flexibility. For this mission, the vehicle was integrated at the OSC NASA DFRF VAB and Pegasus was then carried to the NASA Kennedy Space Center by the NASA B-52 and launched near the Florida coast. Seven launches are scheduled to occur within the next 12 months and future annual launch rates offourto six missions per year are planned.

Pegasus is the product of a three year privately funded joint venture of Orbital Sciences Corpora­tion (OSC) and Hercules Aerospace Company. A "Turn-KeyW launch service is provided, with OSC and Hercules responsible for all hardware and services necessary to deliver the payload(s) to the desired orbit. The standard Pegasus launch ser­vice includes design and production of the vehicle, mission specific hardware and integration support, payload integration, vehicle integration facUities, ground support equipment, carrier aircraft, and launch operations. The first six Pegasus missions were funded by DARPA as part of its Advanced Space Technology Program (ASTP) through the Advanced Vehicle Systems Technology Office (AVSTO). Support was also received from the NASA DFRF and the Air Force Space Division through agreements with DARPA. The vehicle was selected in 1991 as the U. S. Air Force Small Launch Vehicle (SLV) and by NASA for the Small

Stage 3 Motor

SecondIThird Stage Separation Joint

Expendable Launch Vehicle Services (SELVS) program. The vehicle has also been selected by commercial customers and by foreign govern­ments.

Baseline Vehicle Description

The baseline Pegasus vehicle (Figure 2) is 15.2 m (50 ft) long, has a diameter of 1.3 m (50 in), and weighs 19,000 Kg (42,000 Ibs). Major compo­nents include three solid-propellant rocket motors, a delta wing, aft skirt assembly supporting three moveable aerodynamic fins, avionics/payload sup­port structure, a two-piece payload fairing, two standard payload separation systems (23 and 38 inch diameter). an optional restartable Hydrazine (N2H4) Auxiliary Propulsion System (HAPS). and the PegaStar<i' integrated spacecraft bus.2

The vehicle's three Solid Rocket Motors (SRMs) and payload fairing were developed specifically for Pegasus by HerculesAerospace. The SRMs have carbon composite cases and use HTPB class 1.3 propellant. The 6.7 m (22 ft) carbon composite delta wing provides lift during the early phases of flight. Three foam core graphite composite fins, which are controlled by electro-mechanical actua­tors, provide aerodynamic control through the end of Stage 1 operation. Pitch and yaw control during Stage 2 and Stage 3 burn is provided by electro­mechanical thrust vector control (TVC) actuators. Roll control after Stage 1 separation, and three­axis control during coast phases and post orbital insertion maneuvers. is provided by 55 N (12.5 Ib) and 110 N (25 Ib) nitrogen cold gas thrusters

First/Second Stage Separation Joint

Stage 1 Motor N2 Tank

or Hydrazine Auxiliary Propulsion

System (HAPS)

Payload Fairing Stage 2 Motor

Figure 2. Pegasus Cutaway Drawing.

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located on the avionics subsystem. A graphite composite avionics structure supports the payload and most vehicle avionics. A 1.3 m (50 in) outside diameter pyrotechnically separated two-piece graphite composite payload fairing encloses the payload, avionics subsystem, and S3 motor. Two standard marmon clamp type payload separation systems (23 and 38 inch diameter) are available. The optional Hydrazine Auxiliary Propulsion Sys­tem (HAPS) provides up to 73 kg (160 Ib) of N2H4 for orbit raising and/or precision orbital adjust­ment. When combined with the vehicle's on-board Global Positioning System (GPS) receiver, HAPS provides autonomous precision orbit injection ca­pability. The PegaStar spacecraft bus can provide extended (5 to 10 year) on-orbit payload and sensor support including attitude control (three­axis, nadir pointing or spin stabilized), orbital make­up and adjustment propulsion, data storage, elec­trical power, and telemetry support for a wide variety of applications. 1

Pegasus vehicles are currently integrated at asc's Vehicle Integration Building (VAB) located at the NASA Dryden Flight Research Facility, Edwards AFB, CA (NASA DFRF). This 60 ft. x 80 ft. facility (Figure 3) is capable of processing one vehicle at a time. Vehicle integration is performed horizontally, using custom motor handling dollies and ground support equipment (GSE). During integration all vehicle components and subsystems are thoroughly tested using Personal Computer (PC) based electrical GSE and other conventional test equipment.

For launch, Pegasus is carried aloft by a NASA DFRF B-52-008 carrier aircraft, to a nominal level­flight drop condition of 12,200 m (40,000 ft) at high

Figure 3. Pegasus Vehicle Assembly Building. Dryden Flight Research Facility. Edwards AFB, CA.

3

subsonic velocity. After release, the vehicle free falls· to clear the carrier aircraft, while executing a pitch-up maneuver to achieve the proper attitude for motor ignition. After Stage 1 ignition, the vehicle follows a lifting-ascent trajectory to orbit (Figure 4).

Pegasus XL Concem

It was recognized early in the Pegasus pro­gram that additional payload capability would be needed for some missions. While providing preci­sion orbital insertion capability for all orbits (Figure 5), HAPS can provide significant additional pay­load capability only for higher orbits. To identify the most cost effective means of improving payload performance for all orbits, a series of trade studies were undertaken beginning in early 1991. The ground rules for these studies were to improve the payload delivery capability to the maximum extent possible while minimizing the scope of the required modifications (to reduce development time, risk, and cost), to maintain the vehicle's overall reliabil­ity goal (currently calculated at 97%), and to mini­mize the impact on payload interfaces and envi­ronments (so that existing payloads designed for Pegasus could be flown on either vehicle).

Upon completion of the trade study evalua­tions, a conceptual design review for the Pegasus XL vehicle was conducted in December 1991. After reviews and discussions with NASA, the US Air Force, and other customers a final vehicle configuration was selected and the design frozen in February 1992. A formal system Preliminary Design Review (PDR) followed in May 92, with a final System Critical Design Review (CDR) in April 1993. The product of this effort (Figure 6), the Pegasus XL vehicle, is 16.8 m (55 ft) long and weighs 22.300 Kg (49.000 Ibs).

Propulsion

The Solid Rocket Motors (SRMs) for the base­line Pegasus vehicle were originally designed us­ing a very conservative 1.4 factor of safety. Based on the baseline vehicle SRM static fire results and flight data it was determined that margins could be reduced to a more traditional 1.25 without compro­mising vehicle reliability. However, simply modify­ing the design to reduce the design factors of safety (resulting in a decrease in vehicle's inert weight) could not provide the level of performance improvement desired. It became clear early in the

Page 4: Pegasus XL Development and L-1011 Pegasus Carrier Aircraft

Launch t.o sec

Second Stage Third Stage Burnout Ignition t.166 sec t ... 594 sec h = 208,340 m h ... 739 km (399 nmi)

h .. 11.582 m (38.oo0 tt) M =0.79 \

~ (683,661 tt) Second Stagel v = 4,564 m/s (14.975 Ips)

v = 5,469 m/s Third Stage 2 0 d Coast y.... egl (17.944 Ips)

y- 25.7 deg. !

First Stage Ignition t= 5 sec h =11,473 m

(37.643 It)

~

Maxq 1,018psf (48.8 kPa)

First Stage 1 _--'----~----o Bumout ~ / t .. 76 sec ~

(195.637 It) 0 ~. __ _ h .. 59,630 m /-

M=7.9 Payload Fairing Separation t= 112 sec

Third Stage Bumout and Orbital Insertion t= 660 sec h ... 741 km (400 nmi) v ... 7,487 mls

.) \ t\ h ... 109,980 m (360,830 tt)

v ... 2.765m1s (9.071 fps)

(24.565 Ips) 1= 0.0 deg.

Second Stage Ignition t '" 95.3 sec h ... 87,512 m (287.113 It) y= 33.0deg.

'---------~ ~-----_./ '------------~ -----------~--"" 'v' --.....,..-Aerodynamic Attitude TVC Attitude Control (Pitch & Yaw)

Control (Fins) Cold Gas RCS (Roll)

Figure 4. Typical Pegasus XL Mission Profile to 741 Km (400 nmi) Circular, Polar Orbit with a 230 Kg (509 Ibm) Payload.

1,000

900

~ 800

'0 til

~ 700 til a.. '0 600 S e til a. <II fi} 500 c: 0 z

400

300

200

, .. :- - - - ............. -I - - - ............ -:.. -..

" " : -"

XL

XL w/PIK Standard Standard wIPIK

'I .......... I , I I t ------ "-""," ... _- _... - ...... _ ... _ .... _~-.... -..;, .. .:, -_ .. "'r- ...... ---- ---:--- -_ .. -- .. --:- .. - .......... -.. ! ... - .. --: "'. ; - ..... :_.... I ' * • , •••• t • I - ..... _: l •

_______ ... _,: _______ ~·~~:·:.: .... A ..... -- ... :----- ........ j I .., f I t -,.." ••• ~...... t ---- .. -----I-·--- .............. :- .. -.. -.;,-----:----------~----------: , ......... " .. "~ .. ,, ! - - - - , I " : : ." ...... l f • -._

-_ .... _-_ .. "" --,-- -_ .. -_ .. --~ --- .. -- _ .... .... :···,: ........ r .... ; -:--- -- - ...... - -:- ................. - t - - ~-""'-4iii,.-..::.'" ., I I -1.,.... •

:' I : : ....... ,. ..... ;........ •

• • ., t 1 I ••• •• ".1 ________ .... ___ ..... _ ... "" .... '" ... __ .. _"" .. _ ..... l.. ___ ..... __ , .. __ .... __ ... ___ l.. _________ .. l.. --- --- --'_ .. _ .. - -_ ... _ .... ' .... _T- ....... '"

: : : :, : : : : .... .. • • t t" I : : •

---------~-------~~~~--'I : . ... ___ .. __ "'""' _ .... _ ....... _ .......... - <0. .... __ .... .-._ .. · ~ : :

" " 100 200 300 400 500 600 700 800 900 1000

Circular Orbit Altitude (nmi)

Figure 5. Pegasus Performance (0 Deg Inclination).

4

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'Optional Configurations Are Also Available "Optional 4th Stage Available for Precision Injection

Figure 6. Expanded View of Pegasus XL Configuration.

configuration trade study process, that the size of the SRMs (in terms of total propellant load) would have to be increased. Conversion of one or more stages to a liquid mono- or bi-propellant configura­tion is under consideration, however the develop­ment time, risk, and cost rendered this option not cost effective for a near term vehicle upgrade.

To retain compatibility with existing tooling, ground support equipment and procedures, the baseline vehicle's 50 inch motor diameter was retained. A series of trade studies were conducted to optimized the increased propellant load (Figure 7) consistent with the program's performance and cost objectives. Factors considered during this parametric study phase included vehicle perfor­mance; development cost, risk and schedule; re­curring cost; and the impact on production tooling, ground support equipment (GSE). vehicle integra­tion, and carrier aircraft.

The final Pegasus XL vehicle design increases the propellant load in the Stage 1 motor by 6.372 Lbm (a 24% propellant increase resulting in a 55.4 inch extension of the motor case). The Stage 2

5

800

750 - Stretch Sl & S2

700 :e 650

- -0- - Stretch S 1 - .. - Stretch S2

0 . . , . .9 600 -0 550 <tl 0 >- 500 <II a.

450

400

-_.-_. -~- ---. -- -~- ," -'---is .. ---- . : : : ,..,;:

- -- - _ ..... ;- - - - - _ ... 'OO r -- - -~~~...". - - - --:- - - - ----

j ..". I •

~~~ ~~~. ;~~~~ .. a:;':=f:::':':~~~~~~ .. $~:-::---:"~~---- ~. --~-------

, , 350

0 0.1 0.2 0.3 0.4 0.5 Stage Stretch

Figure 7. Stretch Motor Performance, Stage 1 and Stage 2 (400 nm 90 Oeg).

SRM propellant load has been increased by 2,021 Lbm (a 30% increase resulting in a 17.7 inch extension of the motor case) In addition, the S2 SRM internal propellant fin design was modified to tailor the motor's thrust vs. time performance to reduce peak (end-of-burn) vehicle acceleration. The Stage 3 SRM propellant load was not changed from the baseline Pegasus vehicle, however its

Page 6: Pegasus XL Development and L-1011 Pegasus Carrier Aircraft

nozzle throat diameter was decreased somewhat to increase the motor's Maximum Expected Oper­ating Pressure (MEOP) resulting in higher perfor­mance. After the final SRM configuration was selection in February 1992, Hercules Aerospace completed the detailed motor design, leading up to a propulsion system Preliminary Design Review (PDR) in June 1992, fabrication of the first SRM's of each type in the fall and winter of 1992193 and finally by static firing of both motor types in the spring of 1993 (Stage 2 was successfully static fired on 22 May 1993 and the Stage 1 motor on 12 June 1993). 80th SRM static fire tests were completely successfully and the performance re­sults are as expected.

Structures

Once the optimum motor size was determined, the remaining vehicle structural components were reviewed and modified as required. Significant changes to the vehicle's structural components included the Stage 1 case SRM to Wing saddle and struts, carbon composite wing, aluminum aft skirt, and graphite avionics structure. Stage 1 saddle modifications were limited to increasing the material thickness in select local areas to support the vehicle's increased weight. The wing support struts were modified to increase load carrying capability and reduce manufacturing complexity. A "5th hook" attachment point was added on the forward skirt of the Stage 2 SRM to reduce the post-release lateral acceleration transient. Struc­turalload testing of both the Stage 1 and Stage 2 SRM cases were successfully completed in Febru­ary 1993. The aluminum aft skirt was modified to incorporate a fin anhedral (23 degrees) to clear the L-1011 gear doors and improve vehicle lateral stability. The baseline Pegasus vehicle's wing size and shape was not changed for Pegasus XL, however select material and other local internal modifications were required to handle the higher captive carry and flight aerodynamic loads. A structural load test on the Pegasus XL wing was successfully completed on 5 August 1993. The Pegasus XL avionics structure has been com­pletely re-designed to maintain a 'constant 38" diameter from the Stage 3 forward skirt to the payload interface (the baseline Pegasus avionics structure provided a 23· diameter payload inter­face). This modification reduced the structure's height (which provides a somewhat increased payload envelope for some applications) and pro­vides a 38" diameter attachment capability which

6

is more appropriate for some heavier payloads. A 38" to 23" adapter has been qualified to allow existing payloads designed for the 23" interface to be flown on the XL vehicle.

Avionics

The Pegasus avionics subsystem provides monitoring and control of the vehicle throughout captive carry flight, launch, and post-orbital inser­tion maneuvers and operations. It's major func­tions include guidance, navigation and control (GN&C), sequencing and pyrotechnic device ini­tiation, electrical power distribution and control, telemetry and tracking, and flight safety functions. The baseline Pegasus all digital avionics system (Figure 8) is simple, and robust. The only modifi­cations required for Pegasus XL are GN&C soft­ware changes to account for the new vehicle's dynamic and aerodynamic differences (all rela­tively minor) and increases in the vehicle harness length to account for the longer Stage 1 and Stage 2 SRMs.

To improve the vehicle's avionics capability, several design improvements and upgrades were incorporated. These changes include: upgrading the vehicle's flight computer from the current 6U VME Motorola 68020/68000 based flight computer to a smaller, lighter weight, and lower power 3U VME Motorola 68030/68302 based system, modi­fying the vehicle's flight safety system to comply with recent range safety directives (to incorporate physical separation of the two independent range safety systems); and minor re-packaging of some components to improve manufacturing and test­ing. All changes have been incorporated and are completing qualification testing.

Carrier Aircraft

The increased weight and size of Pegasus XL. combined with operational requirements (such as extended captive carry requirements for equatorial missions and requirements for payload monitoring and control capabilities on-board the carrier air­craft) made it necessary to identify and implement an alternative for the current NASA OFRF 8-52-008 carrier aircraft. A study was initiated in late 1991 to identify the optimum carrie r aircraft for long term Pegasus launch operations. Some of the aircraft considered included the B-52G, Boeing 747, OC-lO. and Lockheed L-1011. Some of the factors considered included performance capabil-

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Page 7: Pegasus XL Development and L-1011 Pegasus Carrier Aircraft

- - - - -Ca rrier Aircraft

- -Carrier Aircraft

ASE

-------Pegasus Vehicle

Analog & Discrete Instr

Stage 1

-

.----'---.

- - - - - -

Analog & Discrete Instr I Analog & Discrete Instr

I

- -

c o

- -

;: ~~-...,.-~--... 1--"'" f! Payload

I ~~~~ts Payload

" 3 >. I-----r----i IU n.

-

Page 8: Pegasus XL Development and L-1011 Pegasus Carrier Aircraft

ity (altitude and speed capability for launch), air­craft range (both ferry and launch), modification complexity and cost, aircraft availability, acquisi­tion cost and operational costs. Following a de­tailed trade study, the Lockheed L-1011 was se­lected for conversion to serve as a Pegasus carrier aircraft. Orbital Sciences acquired a L-1011 air­craft in May 1992, modifications to carry Pegasus are complete, and the aircraft is currently undergo­ing certification testing. The L-1011 is scheduled to be operational in the Fall of 1993.

The major modifications which have been per­formed to configure the L-1011 for use as a Pe­gasus carrier aircraft (Figure 9) include deletion of all unnecessary equipment and addition of equip­ment required to support Pegasus launch opera­tions (a release mechanism; an opening for the Pegasus vertical stabilizer; equipment for monitor­ing and controlling Pegasus during captive carry flight; payload air-conditioning and nitrogen purge systems, and external video cameras).

Pegasus is attached to the L-1011 using four hydraulically actuated release hooks which inter­face with fittings inside the Pegasus wing (Figure 10). This interface is identical to that used for the

baseline Pegasus vehicle. This release mecha­nism is attached directly to the L-1011 center wing box which has been strengthened by the addition of internal reinforcements, doublers and ribs (Fig­ure 11). A forward "fifth hook" was added, which attaches to Pegasus on the forward skirt of the Stage 2 motor case. This forward attachment provides a constant 5,000 Ibf vertical force on the vehicle during captive carry flight and it's release timing relative to the main hooks is tightly con­trolled to minimize the post release lateral tran­sient.

To monitor and control Pegasus and its pay­load during captive carry flight a Pegasus Launch Panel Operator's (LPO) station has been installed aft of the cockpit area. From this station an OSC LPO can monitor Pegasus during flight and pre­pares the vehicle for launch. A second position at the station is available for an on-board payload representative (subject to FAA approval) and space is available in the LPO station for mission specific payload support equipment. A payload air-condi­tioning system on the L-1 011 will maintain payload temperature throughout captive carry flight. Two external video cameras are installed to allow the LPO operator to examine the vehicle during flight.

Air Conditioning System Pallet

Nitrogen Purgel

Cooling Reservoir

Avionics Pallet

Pay­load

Pegasus Launch Vehicle

5 Twisted Pair

4 Discrete Cmds

4 Talkbacks

Pegasus Wing

LPO Station

Figure 9. PegasuS/L-1011 Interface Details.

Payload Fairing

8

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Figure 10. Pegasus L-1011 Release Mechanism.

Figure 11. L-1011 Wing Box Internal Reinforcement

The modified L-1011 Pegasus carrier aircraft is capable of supporting both the baseline and Pegasus XL vehicles. While carrying Pegasus it provides a non-stop ferry range of over 4,500 nmi and a launch mission radius of over 1 ,000 nmi.

Vehicle Integration

Pegasus final integration requires minimal fa­cilities and ground support equipment (GSE). Prior to delivery to the field integration site, aU Pegasus components are integrated and tested to the high­est possible levels. Horizontal integration (Figure 12) eliminates need for high-bays or equipment capable of lifting motor segments or other vehicle components. The facility must provided adequate air-conditioned floor space, be approved for pro­cessing the required quantities of propellant, and have access to a suitable runway.

The current Pegasus NASA DFRF VAB is limited to processing one vehicle at a time.

9

Figure 12. Pegasus Vehicle Integration.

Future launch rates and other program re­quirements made it necessary to find larger facili­ties for the long term program. Following a source selection study, two sites were identified as opti­mum for long term Pegasus launch operations: Vandenberg Air Force Base (VAFB AFB) on the west coast and NASA Wallops Flight Facility (NASA WFF) on the east coast. These two assemblyl production facilities, which will be activated in 1993-1994, will provide full scale production and payload integration facilities on both U.S. Coasts

The VAFB VAB (Figure 13) can support pro­cessing of multiple launch vehicles and payloads. In addition to production support and in-process vehicle component storage areas, the VAFB VAB (Figure 14) provides two 6,000 Square foot vehicle processing high-bays and over 600 Square foot of adjacent payload processing areas. The VAFB VAS is currently in the final phases of activation and will be ready for SRM delivery and Pegasus XL processing in September 1993.

Figure 13. Pegasus Vandenberg AFB Vehicle Assembly Building.

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20Wx20'H Roll-Up Door

VehiCle Processing Bay 2

Clean Tent I' :~

ewx 10'H Ron-Up Door

Operalions Planning Area

She Engineers & Technical Staff

118 Feet

Vehicle Processing Bay 1 6,000 Sq Ft

~

Fl TComponenl Bonded Storage

Area

50 Feet

50 Feet

Men's

10 in COncrele Blast Wall

15Wx12'H Roll-Up Door

All Storage Area 32 Feet

Figure 14. Vandenberg AFB Pegasus VAB General Layout (to Scale).

10

T a; ., 1.1. ... U'I

25Wx2O'H Roll-Up Door

25W x20'H Roll-Up Door

54 Feel

14 Ft Wide Sliding Door (Replaces existing

12 f1wide Sliding door)

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The NASA WFF VAB (Figure 15) can also support the processing of multiple launch vehicles and payloads. The NASA WFF VAB (Figure 16) provides 8,000 square foot of vehicle production area of which over 600 square foot is available for on-site payload processing. Design of the NASA WFF VAB is underway and activation of the facility is planned for 1994.

Figure 15. Pegasus NASA WFF VAB.

ISO' 11.5'H x 12'W 11.S'H x 20'W

Door Door ::~ ;~;

i " 2S' x 30'

I Hydrazine loading

~ Area

! Storage

Area

12'H x 20'W Door

i $.! ~a ;:; Secure ~

m Storage

i i

I

Both the VAFB VAB and the NASA WFF VAB are environmentally controlled and maintain the vehicle processing area at 74 +/ - 10 degrees F and 40 +/- 10% relative humidity. The VABs are maintained in a visibly clean condition for vehicle integration and portable clean room facilities are available for processing sensitive payloads on a mission specific basis up to class 10,000.3 Both facilities can support on-site hydrazine fueling operations for loading the Pegasus HAPS (when flown) and for fueling payloads (when required). OSC provided hydrazine propellant ground pro­cessing equipment (GSE) will be available at both sites.

payload Capability and Interfaces

Pegasus XL's payload capability, as com­pared with the baseline Pegasus vehicle, is sum­marized in Figure 5. Information regarding pay­load performance to elliptical and other inclination orbits can be found in the Pegasus Payload Users Guide.4

Pegasus XL utilizes the same payload fairing as the baseline vehicle and can support payloads as large as 1.8 m (72 in) long and 1.2 m (46 in) in diameter(Figure 17}. Thefairing can be extended

100' 1 1 //{ I 11

( « <11

J \J ~\ '\

24' X 12' X 12' H lS'H x25'W Payload Processing Door

Clean Tent

I /

~ a

: ~I c I , I

i

0'

I ,

Figure 16. Pegasus VAB at NASA WFF General Layout (to Scale).

11

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180" +38' Payload Separation System

Stayout Zone

Note: Fairing Door Location Is Flexible Within a Specific Region.

84.22

Stayout Zone Clamp/Separation System Components

270"

Forward View Looking Aft

13.00

43.72

· 1 · 1 , .

. C·······~··-·--------J·· . '/ 29.92 i ' .... : 'I " f ,

f • f • t ,

: I · i I

:~ 1 R 106.00

~ 1

Payload Access Cutout 13.00 X 8.5

· · · ·

Payload Interface Plane (For Payload Separation

System A20066) i-------i-- <jl46.00 ---:

Payload Interface Plane (For Non-Separating Payloads)

38' Avionics Thrust Tube (22.oo Long)

3.95

Dimensions in Inches

5.00

1----- cfJ 39.50 -----1

Side View

Figure 17. Payload Fairing Dynamic Envelope With 38 Inch Diameter Payload Interface.

12

. .

Payload Dynamic Envelope

Fairing

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up to an additional 60 cm (24 in) and access doors can be repositioned or added as optional services. The payload captive carry and launch environment for the Pegasus XL vehicle is very similar to the baseline Pegasus vehicle (Figure 18.a through Figure 18.d). The air launched method subjects payloads to relatively low structural and environ­mental loads compared with typical ground launch vehicles. Detailed information relative to payload design loads can be found in the references.'·5

Event

Taxi, Captive Flight

Drop Transient

Aerodynamic Pull-Up

Acceleration Level, (g's)

Lateral at SIC

Axial Separation Plane

Horizontal Vertical

:t1.0 :to.5 +2.2/1.0

0.0 :tl.0 :1:4.0

·4.2 :1:1.5 +3.6

N

~

Stage Bum-Out . :1:1.2 :1:1.2

Abort Landing :to.6 ±0.6 ±3.5

"Dependent on Payload Mass

•• Assumes a Payload Fundamental Lateral Frequency

Greater than 20 Hz when Hardmounted at the

Payload Separation Plane.

Figure 18.a. Pegasus Payload Acceleration Environment.

0.1 ~----~--~--~~~~~ __ -_-__ -_-_-_~ __ -.-__ -_~ __ -_-___ .-_-_.~_~_.-_T._~.-_.~~~ __ -----_.-.~ .. -.-_-.. -.-.. -.~.~_._-_-.-__ ~ ____ ~.I _ _ ~ _~____ _k _____ ~ ___ .. _~~ ~ .. _ .. _ .. ~_

_ ~ __ L_______ _ ___ ~---~-_~- :_~-~-~~-- __ ~t .. _ .. _ ,J _ ... _ 1. _ , , , • I

~ .... ~ __ .. __ "' __ .. 4."'.0. ... __ . _~. __ "" ~-1 I • j Ii"

- , ~ ,. - - - - - - - - - r - - - r - - 1 - r 't - , - r ., - .• 0.05 .. -- ... -----~ -- ... --- .. -- -~ -~-------~-~

,- • r - ., - -: - • -

---------I.-----~---.-- ... ~- .. ---- ... - ~~~--~-- .. -~- .. -.. ~--------- .. , . . ! I I 1 I I • , . , . I • , j I j , ' , , , , , . , ------r-----,- r- - ~ 'i -r -T -'--r-l , r~--'-'-----~ ,-.-;--~-,- 'j ·I--.~i-

, • , • I

0.02 - ~ - - - - - .. - - - " -• r • I , j

- -- - - -,.. "- . - ~ - ~ .. - - -,- - " -.... --- .. -, • I " , ,

, , I , I t I I I I I , • , ••• , •

! , I I I t j ! •• , I ••

0.01

~~~~~~~~~f~ -: :~~:~~~~ --- :;::.:: :=: --~ ~~~ ~ ~E~t~~-~~~:~~~~~I~66:~~~~~~~~i: ~~ ~ p~: m~ 0.005

_________ ~_. ___ ~ ___ ~ _____ 4_~_._~ _________ ~. ____ ~_*_. __ ~ __ ~_~_~ ~ _________ ~ ____ ~ ___ ~ ., __ ~ ~-.-~-

• ( I j I , :_~_~_~_~_ ~ ~_~_:_

--20 HzI.OO4/g2/Hz- - { -:- - ~ - -:- -:- ~-I • , •• , • 1 , •• I , I'

Cl) 0.002 I 1 , 1 , ! I ! I ___ _ _ ~ _____ ~ ___ ~_ ~_J_~_~_L __ _

• , I , f .. ___ ' __ .. _ ... _... l.

I ( , I I , ___ L _____ L ___ l. __ ~ __ l._~_~_l.~ ___ _

I , I , , t' • j I !

0.001

0.0005

0.0002

______ It.­

-------1. _________ .i. ___ _

.. ________ .1 __

-------T---

\ : ! I ! I I I I , !

, I , ' , • , , , , , , , , .. , • I • ! I I ! , , , • ,

.1... __ .... __ I- .. _ J _ I- .t. _ _ _ _ _ _ _ _ _

_ _______ L

--------~~--------~f"'-

_ ~_ ~--;-~-~ ~_~ ________ L _____ ~ ___ ~_-~.-~-~ _________ .i. _____ L_

, ___ ~_.i. _____ L ___ .i. __ ~ __ I._~_~_~_L _____ L _____ L~

; , t ••• I • ,

,. ----:..---~-~-'" , .

Flight Limit Level 2.88 Grms ~ ~~L _____ J... __

Frequency (Hz)

Figure 18.b. Payload Random Vibration Environment.

13

( , , , ,

:200ri Hz!~QQ1'g~ll:lz:~: ~: __ l. __ ~l. _' __ .i.. ..I~.J_l. _ _~_~_L __ ; __ ;_ ;_

• - t - - - r - - .,- - (- T-_ ~ __ L _ ~ ~, __ I. _ ~ 1 _

_t ___ L ___ ' __ ' _1. _

Page 14: Pegasus XL Development and L-1011 Pegasus Carrier Aircraft

10,000 ----¥·-------T-------_~--w--r---~--h~--~.-~-.~-T--~.-- ----·---r-------~------r-~-~---

U)

C:I

5,000

2,000

1,000

500

200

100

50

20

-------------~--------r--~--r---~---~--~--~--r-T-----w-------·r-~-----~------r---'-------.. -------.--------~--~--~---~---~-.~ .. ~~-~-.----------.. --~--.----~------~---~----------------~--------~-----~~--~---~--~--~--~-.---------.----~-------~------~---~----------------f------·-~-----~---~---~--4--~--~-I----~--------~~-----~-~~-----~---~---

I I • I I I I I I I I , I

-···---------,--------r-----r~--'---,--'--~--r-T--------------r----·--~------r---'---, J • I I I I 1 I ,I I I

-------------~--------~-----~---~---~--~--~--~-.---------~~---~----~--.---.~-~---~---, I , I I I ,t I t ~ tit I I I • I • til

-------- --- ---I --. --- --:- -----:- ---;---;--'1- --:- -roo t .. ---- .. -- --- .. ..... r- .. --- ---: ... -.. ---:- -- -'1---, I' • I I I It' I I

I • I , I tit • I I • • • I , I • t I

ttl I I I 1 I 1 I t I I _ ...... __ ... _____ .. _.I. _ .. ______ '" ___ .. _"' .. __ J ___ J. _J_ .. J _ _ "'_1 _____ .. ________ "'_ ...... ____ t .. __ ................ j _ _ _ _ .... __ • _______ .I. ________ "' _____ ~ ___ J ___ J __ J __ J __ ~_1 ___________ '"' __ ~_~~ ____ J .. _____ "' ___ j __ _

t • • • i i t I I ,t 1 I

::::: ::: ::: ::~ ::: ::: ::~ :::::~:::~:: :~:: ~::~::~ 1"3001450:: :::~::::: ::~::::::~:::::::: _____________ J __ ~ _____ ~w ____ ~ ___ j ___ j __ J __ j __ L_. ______ ________ ~ __ w_. __ J ______ ~ ___ j __ _

t • I I I , • f t f t J , _____________ ~--------~-----~---~---~--~--~--~-L- _____________________ _ .. -----------~--------~-- .. --~---~---~--~-- ~ -}-----------. Flight Limit Level

-... ""-- .... _,. .. ::~::~ ::~: ..... ..01 __ .... _ .....

---:--1 .. -1-· . , --., ..... ' ... "'r .. · .. .. -~ .......... ~ ... · , , · .. ---:-.-I ..... }. , . .. . . · .. __ .J __ J_ ... I. _ __ ..J __ J __ I._ · .. --":"'-i .. -t--:::10,000/400

, .. --i .. -4 .. -t-, .. , , . . . , , . , ...... ..01 ...... " .. _ ..... ..... ,---'"'!"--~-~~ ~ :

· · . I , I fit "

-------.-----.--------~. --~--~~~- .. ~ .. ~--~--~-.-------------- ... -.-----~------~---~---~--~.-,,-~.--.. ----------,--.~.--- -·~-r---~---~·-~~·~- .. r-~--------------r-------~·- .. ---~~--,- ~.-""-- .. --,.--.. ~---------,--.-~. ~".--Mr---.,-- .. ~--~--~--r-T-----.----- .. --r-------~-- .... - -r-·-'---~·-""--,--,.-_____________ ~___ _ __ ~ __ • ___ • __ ..oI_._..oI __ • __ • __ ~_. _____ ._ .. _____ .. ____ ~ ___ ~ __ .. _______ ..oI ___ • __ ..oIM_ .. __ ~ _ _____________ J. _____ ~ _____ ~ __ .~ ___ ~._~ __ ~ __ ~_4 __ .. __ .. _____ w __ ~._._ .. __ ~ ______ ~_~_~ ___ ~ __ ~ __ J_~L.

t I , I t I I , I I ~ I , I • •

~-~~.----~---.-~--.""--.~--""~-~- .. ,.-~- .. -- .. --------.r-.-- ___ ~--·-- .. r--_'-M-~--~.-~--,.. • t I I I I •• ·------r-------,------r-··'---,--'--'--r-

, • , , I ~ I t I I tit I I • • __ _ ________ l ________ ~ _____ ~ .. __ J ___ ~ __ J __ ~ __ ~_, __________ ____ L __ ._._.J ______ ~_ .. _j_ .. _J __ J._J __ L

....... ---- ---- -~ -- Q=10 r----:-- --:- --:- .. ""!- -:--- r-,.. .. --,..- --_ .. -- -:- ... -- ..... : ...... ---~ ---'"!- ~- ~ ... - ; .. - ~ --f'" I It. t f f f t f ~ • I I I I I I t fit ttl I I f I I ••

100/25 : l3' : : : : : : : :::: ~ : : ~ 10~--________ ~· ______ ~ __ ~· __ ~· __ ~' __ ~·~'~·~' __________ ~·~ ____ ~· ____ ~· __ ~: __ ~:--~'~:~:~ 100 200 300 500 1,000

Frequency (Hz)

2,000 3,000 5,000 10,000

Figure 18.c. Pegasus XL Launch Environments (Shock at the Payload Interface Excluding Payload Separation System).

T. mp Range3 Humidity Purity Environment Control

OegC OegF (%) Class 2

VAB/Ground Operations 18 to 29 64 to 84 Filtered AlC 1 <50 100K

Carrier Mate 18 to 29 64 to 84 Filtered AlC <60 100K

L-1 011 Taxi 18 to 29 64 to 84 Filtered AlC <60 100K

L-1 011 Captive Carry 18 to 29 32 to 84 Filtered AlC <60 100K

L-1011 Abort/Contingency Site 18 to 29 32 to 84 Filtered AlC <60 100K

1 Filtered Air Conditioning (AlC) 2 Class 10K Can Be Maintained Throughout Operation on a Mission-Specific Basis.

3 Temperature at AlC Inlet

Figure 18.d. Payload Thermal Environment.

14

I I I I I I I I I I I I I I I I I I I

Page 15: Pegasus XL Development and L-1011 Pegasus Carrier Aircraft

I I I I I I I I I I I I I I I I I I I

Conclusion

Pegasus provides a flexible and cost effective method for placing payloads into low earth orbit. Pegasus XL increases the vehicle's payload capa· bility while retaining the vehicle's simple and ro­bust design to ensure maximum system reliability. Development of the Pegasus XL launch vehicle is nearing completion, with the first launch scheduled to occur in late 1993. Activation of the two new production vehicle processing facilities will allow the program to simultaneously process multiple vehicles on both U.S. Coasts. The transition to the L-l0ll carrier aircraft will significantly improve the Pegasus launch system's operational flexibility.

Aythors

1. Mr. Marty Mosier, Pegasus XL and L-1011 Program Manager, Orbital Sciences Corpo­ration (703) 406-5250

2. Mr. Ed Rutkowski, Pegasus Range Op­erations Manager, Orbital Sciences Corporation (703) 406-5228

References

1 Pegasus First Mission Flight Results, USU/ AIAA Small Satellite Conference, Orbital Sciences Corporation, August 29, 1990.

2 Pegasus Launch Operations and the PegaStar Integrated Spacecraft Bus, IVth European Aerospace Conference (EAC 91 ), Orbital Sciences Corporation. May 16,1991

3 The Pegasus Air Launched Space Booster Payload Interfaces and Processing Proce­dures for Small Optical Payloads, Society of Photo-Optical Instrumentation Engineers (SPI E) Intemational Symposium on Optical Engineering and Photonics in Aerospace Sensing Conference, Orbital Sciences Cor­poration, March 4, 1991.

4 Commercial Pegasus» Launch System Pay­load Users Guide (Release 3.00). 1 Sep­tember 1993.

5 Loadsand Design Criteria - Pegasus Launch Vehicle, Orbital Sciences Corporation DOC A 10020 Revision A.

15

Marty R. Mosier

Mr. Mosier is the Pegasus XL and L-l0l1 Program Manger and has been with the Pegasus program since its inception. Mr. Mosier is respon­sible for all aspects of the development of the Pegasus XL vehicle as well as modification and certification of the L-l011 Pegasus Carrier Air­craft. Prior this assignment. he was Pegasus Program Manager with responsibility for vehicle production, design improvements, field operations and ground support equipment. Mr. Mosier acted as Vehicle Engineerforthe Pegasus development program. He is OSC's chief pilot and is certified as a Pegasus B-52 launch panel operator. Prior to joining OSC, Mr. Mosier was project manager for the Naval Postgraduate School ORION small sat­ellite development program and has held a variety of mechanical and electronic design positions in the aerospace industry. Mr. Mosier is a registered Professional Engineer, holds a MS in Manage­ment from the University of Southern California, and has a BS in Engineering from Harvey Mudd College.

Mr. Ed Rytkowski

Mr. Rutkowski is the Pegasus Range Opera­tions Manger for Orbital sciences Corporation. He has been responsible for completing the transfer of Orbital's operations from the NASA Dryden Flight Research Facility at Edwards Air Force Base to new facilities at both Vandenberg Air Force Base on the West Coast and at the NASA Wallops Flight Facility on the U.S. East Cost. Prior to assuming his most recent responsibilities he was the Space System's Division's Director of Marketing for civil Programs. Mr. Rutkowski was the technical Director for Integrated Systems Ana­lysts, Inc. from 1984 through 1989. Prior to 1984, he completed a 24 year career as a Naval Subma­rine officer. Ed and his family live in Centreville. Virginia.


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