Program updateFebruary, 2017
Unlimited Rights to NASA in accordance with Prime Contract NNJ06TA25C and Subcontract RH6-118203.
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•Space Launch System
•Orion
•Main EngineThrust VectorControl (TVC)
•ActiveThermalControl
•CO2 Removal /HumidityControl
•AvionicsCooling
•PressureControl System
•CabinAirVentilation
•EnvironmentalControl & LifeSupport – SE&I
•Power Management& Distribution
•Active ThermalControl
•Space LaunchSystem
•FireDetection &Suppression
•Power andData Unit(modules)
•AtmosphericMonitoringSystem
•PowerTransientProtectionUnit
•Power andData Unit(modules)
•AuxiliaryBus ControlUnit
NASA SPACE LAUNCH VEHICLE
•Solid RocketBooster
•TVC Power Units
•PowerTransientProtectionUnit
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Orion MPCVThe Orion Multi-Purpose Crew Vehicle (MPCV) isNASA’s first spacecraft designed for long-duration,human-rated deep space exploration
Consists of two main modules:
• Crew Module (CM) - Lockheed Martin
• Service Module (SM) – European SpaceAgency
• SM supports the crew module from launchthrough separation prior to reentry
SM propelled by eight R-4D Auxiliary Enginethrusters
• 110-pound-thrust bipropellant thrusters
CM propelled by 12 MR-104G catalytic thrusters
• Thrust generated by catalyticdecomposition of hydrazine over a heatedmetallic catalyst bed
First test flight - Exploration Flight Test 1 (EFT-1)
• Launched on December 5, 2014 by a Delta IVHeavy rocket
Future missions:
• Exploration Mission – 1 (EM-1) Uncrewed,launched by Space Launch System
• EM-2 Crewed mission, launched by SpaceLaunch System
•4
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•6
•SLS Rockford Content
• 45 IL Employees
•SLS Rockford Content
• 45 IL Employees
•Orion Rockford Content
• 44 IL Employees
•Orion Rockford Content
• 44 IL Employees
•New Technologies backed by 40 years of Proven Human Space and Rocketry Performance
•UTC Aerospace Systems
•Space Launch System (SLS) and Orion•CAPU
•Filter Manifold •Hyd Reservoir
•Hyd. SupplyAccumulator
•CAPU Controller
•Auxiliary Bus ControlUnit (ABCU)
•Portable UtilityPanel (PUP)
•Power TransientProtection Unit for
Launch Abort Systemand Service Module
•(LAS PTPU, SM PTPU)
•Umbilical SwitchCard (USC)
•ECLSS DriveElectronics Card
(EDE)
•Load SwitchCard (LSC)
•28V ConverterCard (28VCC)
•Booster APU
•Ready to support new Exploration Upper Stage with cryogenicfluid handling, power generation & mgmt, and actuation solutions.
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Orion Program• Orion Multi-Purpose Crew
Vehicle (MPCV) is a cross sitesystems level program, withresponsibilities spread acrossseveral UTAS Space Systemssites
• Rockford plant site isresponsible for PowerManagement and Distribution(PMAD) system
•EFT-1Content
•UTAS Content for Orion Capsule
•8
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•9
Radiators
Crew Module
HFE7200(2 loops)
R134a fromGround Cart
Ammonia(2 loops)
•Coolant PumpPackage (CPP1)
•Ammonia Tank
•Cold Plates (17)
•Accumulator (2)
•Maintains Loop Pressure
•Radiator OutletValves
•HX22
•Radiator InletValves
PGW (2 Loops)(Propylene Glycol)
•HX21
•ColdplateBypass
•Ammonia Boiler
•Heat Rejection
•Re-entry / Post Landing
Crew Module Adapter European Service Module
•Fluid Control Assembly (2)(FCA)•Negative
Pressure ReliefValve
Control
•NitrogenPressureControl
T
Control
T
ECLSS SYSTEM OVERVIEW – EM-1•Jettisoned During Re-Entry
•Jettisoned DuringRe-Entry
•Vent Overboard
•Contains FES CCA’s
•Contains FESCCA’s
•CPP1
•Heart of the PGW loop, circulates PGW fluid throughout system andcontrols pulsing valves in ABHX to regulate PGW temperature (4 Pumps/ 2 Coolant Loops)
•FCA
•Heart of SM ATCS system; Circulates HFE7200 throughoutloop (to be cooled by radiators and to cool PGW within HX22)(2 Pumps / 2 Coolant Loops)
•Battery / Avionics Cooling
•Maintains Cabin Pressure
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Orion Power Management And Distribution(PMAD)
•UmbilicalSwitch Card(USC)
•ECLSSDriveElectronicsCard (EDE)
•LoadSwitch Card(LSC)
•28VConverterCard (28VCC)
•Auxiliary Bus ControlUnit (ABCU)
•Power TransientProtection Unit for LAS
and Service Module
•(LAS PTPU, SM PTPU)
•PortableUtility Panel(PUP)
•Power and Data Unit (PDU) Assemblies
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ITL ABCU
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UTAS PDU Card Content
S1 C1 C3 C5
USC
2
2
LSC
1 1 1 1
EDE/
28V1
11
•PDUs
•Cards per String
•4 USCs
•4 LSCs
•6 EDE/28VExport Controlled Information: EAR99
Orion Electric Power System
S1 C1 C3 C5
ABCU
S2 C2 C4 C6
LAS
PTPU
SM
PTPU
Battery
Battery
PCDU
PCDU
Solar
Arrays
Solar
Arrays
•ESA supplied•LM/UTAS
•UTAS•LM
•Service
•Module
•Crew
•Module
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EPS and PMAD
• Aircraft EPS traditional
– Typical 2 Channel, AC generator sources, 28VDC derived fromTRUs and batteries
– Centralized Switches, Relay/Contactor Drives, contact breakerpanels in cockpit (accessible by pilot/flight engineer)
• Aircraft PMAD evolution
– Distributed SPDAs – remote contact breakers with electronicsolid state breakers/switches
– Remote control from flight deck over digital communications(Arinc 429, Ethernet based etc….)
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Space Craft (Human)EPS/PMAD
• Apollo
– 28VDC Fuel Cells(3) SM and Batteries CM (~3-5kW fuel limited)
– Contact Breaker panels crew accessible
• Space Shuttle Orbiter
– 28Vdc Fuel cells(3) and Batteries (~10 – 12 kW fuel limited)
– Remote solid state comms bus (1553?), and pilot accessiblecontact breakers
• International Space Station
– 120Vdc, Solar Array and Batteries (~85kW+ Array/Battery limit)
– Well regulated power to EPCE/Users
– Remote electronic power contactors, computer controlled via MilStd 1553
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Operation/Profile
• Mission energy Profile.
– Important to be able to guarantee that the system has capacity tomeet the full mission needs from launch to recovery
– Detailed planning needed to size the “array and batteries” tomeet needs for all orbital cases, deterioration of components,and faults.
– Or carry enough Fuel in the case of Fuel Cell technology.
– Enough battery power for reentry and recovery
• Power Quality
– Voltage drop, trip characteristics, losses, EPCE (Electrical PowerConsumer Equipment) details…
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Orion EPS and PMAD
• Space vehicle similar to the Apollo
• 120Vdc Dual Bus, Solar Array and Batteries (Li-ion)
– Arrays located in Service Module, Batteries in the Crew Module
– Battery Regulated! (low losses but large voltage range)
– Remote electronic power control, computer controlled via“Ethernet” (T-Tech 1G similar to 787 EPS internal)
• Power Distribution achieved by PDU (Power Data Units)
– PDUs accommodate some utilities, network switching and powercontrol/conversion
– UTAS provides highly integrated “switching elements” as RPCs
– RPCs are able to “current limit” prior to trip during faultconditions. This helps maintain the integrity of the rest of thepower system upstream from the fault.
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Orion – how it’s arranged
• PDU Power Data Units
– 2 in SM, 2 external CM, 2 internal CM
• Batteries (2) feed C1 and C2 and ABCU
• 120Vdc distributed, some 28Vdc
• LAS PTPU
– Power feed toLaunch AbortSystem (basically abig wocket)
– Located in SM toprotect incomingexternal power
• Transient protectionlightning duringlaunch and ascent
• PCDU
– Interface betweenEuropean SM EPSto Orion EPS
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S1 C1 C3 C5
ABCU
S2 C2 C4 C6
LAS
PTPU
SM
PTPU
Battery
Battery
PCDU
PCDU
Solar
Arrays
Solar
Arrays
•ESA supplied
•LM/UTS
•UTAS
•LM
•Service
•Module
•Crew
•Module
Why Remote Power Contactors
• Current Limiting
– Mitigates/limitsupstreamdisturbances
– Voltage acrossdevice proportionalto fault current
– Mimics i2t inversecharacteristic
– More complex,stressful for limitingdevice (SOA)
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•Customer: Boeing•Status: Starting Design, Development, Test & Evaluation
•UTAS is developing sixcomponents for each of thefour thrust vector controlsystems (RS-25 MainEngines gimbaling) onBoeing’s Space LaunchSystem Core Stage.
•Shuttle Orbiter hydrazineAPUs are being converted tocold-gas blow-down units(CAPU) with new technologycontrollers.
SLS CORE STAGE
•APU and Controller
•Hydraulic Circuit Components
•TVC Components
•20
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Space launch system (sls)
RS-25 Engine•SLS 70-metric-ton Initial Configuration
•~3500 psia gaseous hydrogen that powers the CAPU is tapped from the LH2 turbo pump
•21
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Space launch system (SLS)
UTAS supplied (Heritage Shuttle basis)
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CAPU
Aux Power
Unit
HydraulicPump
HydraulicFilter
Manifold
.Gas jet modulated spins
turbine
Hydraulic Fluid(100psi)
Hydraulic Fluid(3200psi)
Reservoir
Directs/Pressurizes /Filters Hydraulic FluidOutput from CAPU
TVC Hydraulic Actuator(gimbals Main Engine Nozzle )
Turbine/Gearboxshaft rotary output -
Return Accumulator
SpeedController
MPU TurbineSpeed
Sensor(s)
Controller modulatesSpeed Control Valve
Port“A”
Port“F”
Port“B”
Hydraulic Fluid(3200psi)
PSV SCV
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Summary
• Rockford has Legacy with NASA Space programs
• Power Distribution in Space has challenges
• Rockford has a significant role in the future of NASAspace programs
We ARE building America’s Next Space Ship
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