Distributed Utility Shuttle Technology

John RazzanoASTE 527Fall 2010

Current NeedAging space shuttle fleet’s retirement is

imminent If the ISS is going to continue operation there

needs to be a replacement to get humans to orbit fast and reliably

Why waste all engineering and infrastructure currently in place for shuttle?

With a burgeoning worldwide space industry a global network of advanced air and space ports will be needed to manage the increased number of flights

DUSTMerge past, existing, and future technologies to

revamp the space shuttle program in 3 step process: Combine American Space Shuttle, Russian Buran, and

current technologiesCreate multiple versions of the shuttle, i.e. passenger

travel, scientific missions, cargo transport etc. Distribute manufacturing and communications around

the world Allow space faring and developing nations to work

together in a similar fashion as the ISS Incorporate private industry for cargo transport and

point-to-point earth travelNot just a vehicle but a globalized architecture

Space Shuttle ProgramReusable high

payload capacity vehicle

Large, complex support system already in place

Expensive program that requires large long term investment

Total thrust of about 12,500 kN

Shuttle MythsCapsules are cheaper than STS

Currently capsules carry 3-4 crew STS capable of 8 up to 12 perhaps

Shuttle MythsShuttle concept and architecture is unsafe

Although ET and SRBs have failed in the past, the orbiter is the safest vehicles

Smooth ride and re-entry that capsules can never offerSTS evolution is expensive - Is it cheaper to start

from clean slate and look for new paradigms or cheaper to insert new and maturing technologies into STS architecture

Shuttle is very expensive compared to capsules With a higher payload capacity is it really more

expensive when compared to these smaller vehicles

Soviet Buran Program Single liquid booster stage

Much smoother launch than the SRB provide on the space shuttle

Most powerful rocket ever created, 29,000 to 32,000 kN

Orbiter does not boost itself into orbit

Booster stage burns up on reentry

Only flown once program cancelled shortly after

Past, Current, and Latest Technologies

SSME is one of the best cryo systems ever made so why change it?

Utilize the Buran liquid booster system Russian Energia (heavy lifting system) can provide

smoother flight and more control than SRBs Capable of lifting 100 metric tons into orbit

The flight testing and design work has already been completed, no need to create a new vehicle and spend time and money doing this again

Update the foam insulation on the space shuttle with latest technology to prevent damage that has occurred in the past

Variations

Private IndustryCorporations such as

SpaceX and Virgin Galactic

Used for point-to-point suborbital travel and earth to LEO (ISS) cargo transportation

How to Build It?:Global Manufacturing

Instead of building the complete aircraft from the ground up in the traditional manner, final assembly would employ just 800 to 1,200 people to join completed subassemblies and to integrate systems

Boeing assigned its global subcontractors to do more assembly themselves and deliver completed subassemblies to Boeing for final assembly Intended to result in a leaner and simpler assembly

line and lower inventory Pre-installed systems reducing final assembly time

by three-quarters to three days.

Case Study: Boeing 787 Global Supply Chain

Unforeseen Problems Intended to shorten the production process,

787 subcontractors initially had difficulty completing the extra work They could not procure the needed parts, perform

the subassembly on schedule, or both, leaving remaining assembly work for Boeing to complete as "traveled work”

From the beginning of 2007 to 2008 the program was delayed 4 times

Global NetworkNetwork of worldwide spaceports built in

countries throughout the worldWill start in the more developed world and

spread to countries that are part of the manufacturing network

Private corporations will be brought in main for cargo transport and point-to-point earth transport

Updated Global Tracking and Data Relay Satellite (TDRS)

First put into service in 1983Goal to increase the amount of time that

spacecraft were in communication with the ground and improve the amount of data that could be transferred3

Third generation network beginning to come online within the next 5 years

Global FAA needed

Way Forward Similar to ISS develop

global coalition to build and develop new shuttle program

Distribute the work throughout the world Perfect the shortcomings

of the Boeing distributed manufacturing method

Allow developing countries to contribute heavily to the network and future ISS operations

Questions

ReferencesBoeing Unveils 787 Final Assembly Factor

y Flow." Boeing. December 6, 2006."Boeing's Big Dream", Fortune Magazine,

May 5, 2008, p. 182. (online version).http://tdrs.gsfc.nasa.gov/