NASA Ares I-X Flight Test plans

8/14/2019 NASA Ares I-X Flight Test plans

1/31


2/31


3/31

IAC-07-D2.6.04 - Ares I-X Flight TestThe Future Begins Here

Figure 2. Ares I-X (right) follows NASA's tradition of incremental development through flight testing, whichhas included the Mercury, Gemini, and Saturn programs (left).

Mission Overview

The Ares I-X Flight Test Vehicle (FTV) willincorporate a mix of flight and mockup hardware(Figure 3), reflecting a mass and weight similarto the operational Ares I. It will be powered by afour-segment solid rocket motor currently in theSpace Shuttle inventory, and will be modified toinclude a fifth spacer segment that makes thebooster approximately the same size and weightas the five-segment SRB. The vehicle alsofeatures a new recovery system, including newmain parachutes. The new main chutes are 150

feet (47.7 m) across, compared to 136 feet (41.4m) across for the Shuttle. Ares I-X will be thefirst flight test of new main parachutes for Ares I.

The Ares I-X flight profile will closelyapproximate the flight conditions that Ares I willexperience through Mach 4.5, at an altitude ofabout 130,000 feet (39,600 m) and through amaximum dynamic pressure (Max Q) ofapproximately 800 pounds per square foot (38.3kPa) (Figure 4). By basing refinements of theAres I vehicle design on Ares I-X information,NASA moves one step closer to full-up test asyou fly scenarios. Each future flight will bestaged to affect future milestone reviews. Ares I-X supports the Ares I Critical Design Review(CDR), scheduled for 2010.


4/31


Orion CrewModule / Launch

Abort System

Avionics (internalthroughout vehicle)

Upper StageSimulator

Figure 3. The Ares I-X provides an early opportunity to test the flight configuration of the Ares I crewlaunch vehicle.

Four-segmentMotor

FirstStage

Roll ControlSystem

First StageAvionics Module

(internal)

SeparationPlane

Simulated FifthSegment


5/31


The Ares I-X mission will be NASAs firstflight test of a new human exploration vehiclesince 1981. As such, it returns the agency to itshistory as a pioneering organization, taking ontechnical risks to develop new space hardware.The five primary test objectives for the Ares I-Xflight test include:

Demonstrating the ascent flight controlsystem performance with dynamicallysimilar hardware.

Demonstrating separation between thefirst and upper stage.

Characterizing and mitigating the rolltorque due to first stage (FS) motorperformance and aerodynamic forces.

Testing the first stage parachute recoverysystem and separation/entry dynamics.

Validating assembly and processing flow,

as well as launch and recovery operations.

These objectives are all attainable using acombination of existing flight hardware andsimulator hardware equipped withenvironmental, acceleration, and other sensors.

Ares I-X provides the first opportunity to testnew assembly, integration, and test (AIT)functions at Kennedy Space Center (KSC).

When vehicle elements begin arriving at KSC byOctober 2008, they will be moved to theAssembly and Refurbishment Facility (ARF),where developmental flight instrumentation (DFI)will be integrated and the upper stage simulator(USS) segments will be stacked in smallersuper stacks to support final assembly of thevehicle in the Vehicle Assembly Building (VAB).

The vehicle will be launched from KSCLaunch Complex (LC) 39B, which will be used

as a backup launch-on-demand facility for theShuttle during the servicing mission (STS-125)in October 2008. Once STS-125 is completed,LC 39B will be transferred to the Ares Projectsfor use on the flight test. Because of its Shuttle-ready state, LC 39B will need to be modifiedslightly to support Ares I-X until a full tear-down

Ground Operations personnel to access theinside of the vehicle prior to launch. The groundsupport systems also include an environmentalcontrol system (ECS) to keep the avionics andground staff cool prior to liftoff. The ECS willhave a T-0 disconnect connection between theground systems and the Flight Test Vehicle(FTV), which remains intact until the first stageignition command (T-0) is issued.

Work continues on Ares I-X design andhardware fabrication. All of the individualelements are undergoing or have completed

CDRs, which were followed by a two-partintegrated vehicle CDR in March and July 2008.

Progress on Mission Hardware and Facilities

The Ares I-X mission was authorized toproceed in spring 2006. Given its rapiddevelopment cycle, hardware design andmanufacturing have occurred nearly

simultaneously to meet the launch date. Thus,while the CDR began in March 2008, much ofthe flight hardware was already well through thefabrication process. The CDR was completedsuccessfully July 24. The various hardwareelements are on schedule to begin deliveries toKSC by October 2008.

First Stage

As noted earlier, the first stage (Figure 5) isusing a four-segment solid rocket motor from theShuttle inventory. New forward structures arebeing manufactured by a contractor partner.These new structures will be heavier than theAres I hardware and will be made mostly ofsteel. The frustum and aeroshell on theoperational Ares I will not be reused and will bemade of carbon composites. The Ares I forward

skirt and forward skirt extension will be made ofaluminum.


6/31


FrustumThe frustum connects the firststage to the upper stage. Machining on thefrustum was completed in June 2008.

Forward Skirt ExtensionThe forwardskirt extension, which houses the MainParachute Support System (MPSS), isscheduled to be delivered to the ARF in late July2008. The Ares I-X separation plane will bebetween the frustum and the forward skirtextension (Figure 6). A field test of theseparation system was conducted at ATKs

Promontory site in July 2008. Work also beganon installing MPSS hardware in July.

Forward SkirtThe forward skirt, whichhelps Ares I-X match the outer mold line of AresI, is due to be delivered to the ARF in late July2008.

Figure 6. The test of the forward skirtextensions separation system verified the

effectiveness of the linear shaped charge and itsshock effects.5th Segment Simulator (5SS)The

structure of the fifth segment simulator (alsocalled 5SS or the XL segment) is 10 percent

complete. The 5SS (Figure 7) houses the FirstStage Avionics Module (FSAM), the FlightTermination System (FTS), and othercomponents. The first of the 5SS componentsarrives at the ARF in July 2008, with additionalsections delivered in August 2008.

First StageAvionics Module(FSAM) S & A and

CRD Panel

Aft

Segment

CenterSegment

Forward

Segment

AccessDoor

Systems Tunnel

Connector Panels

Flight Safety

System (FSS)Antenna

Clevis-TangInterface

BoltedInterfaceLadder /

Cable Tray

S-BandAntenna

C-Band

Antenna

Hybrid andDirectionalCoupler Panel

AccessDoor

ECS

Ports

Batteries and

C-BandController

HeaterCableModule

C-Band

Transponder


7/31


installed. The aft skirt for Ares I-X, whenoperational, will include eight BDMs and fourBTMs. A recent lean event at KSC helpedincrease the schedule margin for the skirt,resulting in a delivery to the RPSF by as muchas one month earlier than originally scheduled.The aft skirt is currently scheduled to bedelivered to the RPSF in October 2008.

Figure 8. The aft skirt, while Shuttle-legacyhardware, will have hardware added to meet the

requirements of Ares I-X.

Separation and DecelerationFivesuccessful drop tests of the parachute system(Figure 9) have been completed so far. Twoadditional tests are planned before April 2009.

Ares I-X will be the first qualification flight test ofthe new 150-foot-diameter main parachutes.

Figure 9. The main parachutes are in the process of fabrication and drop testing.

Avionics

Ares I-X will carry four types of avionicshardware:

commands between the Atlas Vcomponents and the solid-propellant first

erational Flight

stage

Developmental Flight Instrumentation(DFI) and Op


8/31


launch date. Table 1 below lists the activitiesand delivery dates for the avionics.

Table 1. Anticipated delivery dates for Ares I-X avionics

Component(s)Current Status (As

Appropriate)Anticipated

Completion/DeliveryATVC CDR completed June 2007

Fabrication under wayOctober 2008

FSAM CDR completed April 2008 October 2008

Flight Software CDR completed March 2008Test Readiness Review

completed April 2008

March 2009

Ground Software (GroundControl, Command, andCommunications/GC3)

Formal testing under way Delivery to KSC October 2008Installation in MLP by May 2009

Systems Integration LaboratoryVehicle Flight Control TestingFlight Simulation Testing

OngoingOngoing

October 2008May 2009

OFI / DFI Sensors andHarnesses

Sensors acquired or on orderUndergoing Table Top Reviews

as completed

Cable Harnesses

CM/LAS October 2008USS October 2008FS October 2008

OFI HarnessesFS/USS October 2008

Fault Tolerant Inertial NavigationUnit (FTINU)

Qualification testing completeDelivered to United Launch

Alliance in March 2008

Delivery to KSC March 2009

SDA Fabrication begun December2007

August 2008

Upper Stage Simulator

The USS (Figure 10) is made up of cylindricalsegments that will be stacked and integrated atKSC for launch. The USS segments are beingfabricated by NASA personnel at GlennResearch Center (GRC) in Ohio. As notedearlier, GRC is completing the assembly of

these segments, along with their internalstructures (Figure 11).


9/31


Figure 11. This image shows the interior ofthe USS

The USS is a mass simulator. It provides themajority of adjustable ballast for the vehiclesmass, center of gravity (CG), and moment ofinertia distribution. The 2-inch- (5-centimeter)thick ballast plates are approximately 7,000pounds (lbs.) (3,175 kilograms (kg)) each. The

US-1 segment holds 16 plates 2 plates,equaling approximately 112,000 lbs. (50,802 kg)The US-7 segment holds 5 plates 2 plates,weighing approximately 35,000 lbs. (15,875 kg)The total adjustable ballast is around 147,000lbs. (66,678 kg). These ballast plates simulatethe mass of the liquid hydrogen and liquidoxygen that would normally be present in theupper stage propellant tanks in Ares I.

The USS is designed with 11 segments: 5common segments (US-2, 3, 4, 5, 6), 2adjustable ballast segments (US-1 and 7), and 4complex segments (Interstage (IS)-1 and IS-2,Spacecraft Adapter (SA), and Service Module(SM)).

Each segment is approximately 9.5 feet (2.9m) tall to accommodate manufacturing andtransportation constraints. Outer Mold Line(OML) protuberances are all bolted on and

assembled on individual segments prior toshipping except the Ullage Motors (4x) and RollControl System (RoCS) Modules (2x) located onthe US-1 segment. These items will be shippedseparately. An internal access door on US-1 andplatforms and ladders provide access to theentire USS, the FS Frustum, and CM/LAS.

USS has successfully completed threeCritical Design Reviews, which were ordered bysegment complexity, with the Charge 1segments being the least complex and Charge3 incorporating the Roll Control System and

avionics. Charge 1 hardware has already beenfabricated. Charge 2 is due to be completed onschedule. Charge 3 hardware fabrication hasbeen started. Manufacturing processes andprocedures have been successfullydemonstrated. Most of the USS hardware is dueto be shipped to KSC by October 2008.

Roll Control System

The active roll control system (RoCS)provides rotational azimuth control forperforming a 90-degree roll maneuver to orientthe vehicles telemetry antennas after liftoff. Italso will mitigate against adverse roll torques(self- and aero-induced) during ascent. Thenumber of RoCS pulses will be measured inflight and will help inform the RoCS for the finalAres I design. The Roll Control System is anintegral, modular, bi-propellant propulsionsystem housed in the USS Interstage segment(Figure 12). The RoCS uses off-the-shelf andgovernment-furnished equipment (GFE)componentsincluding nitrogen tetroxide andmonomethyl hydrazine propellant tanks, heliumpressurization tanks, and engine nozzles. ThisGFE was harvested from Peacekeeper missiles,then re-integrated into a system for RoCS.


10/31


Duty cycle testing for RoCS was conductedat the White Sands Test Facility in late 2007,and fuel tanking and detanking tests wereperformed at KSC in early 2008. This verificationtesting, performed at Hypergol MaintenanceFacility (HMF):

Demonstrated loading pressurant andpropellant (using de-ionized water) intoPeacekeeper tanks/fill valve configuration

Used HMF GSE planned for RoCS flightmodule loading

Verified and validated procedures andhardware well in advance of actualpropellant loading in flight modules.

The RoCS team is focused on completinghardware fabrication and integrating it into themodules, while working verification activities inparallel, leading to a Hardware AcceptanceReview early September 2008. The RoCS teamhas high confidence that it will meet its deliveryschedule for the 2009 launch.

Crew Module / Launch Abort System Simulator

Like the USS, the CM/LAS portion of Ares I-X will be simulator hardware (Figure 13). Theseforward sections differ slightly from the currentiteration of the Ares I design because Ares I-X

was baselined during an earlier design analysiscycle (DAC). However, the CM/LAS will stillprovide critical information about aerodynamicand acoustic loads on the Orion crew

exploration vehicle. A total of 362 DFI sensorswill be placed on and in the forward structures.The data from these sensors will be transmittedto the ground via telemetry. The sensors mightalso provide visibility into the thrust oscillationissue Ares I is studying. The CM/LAS CDR wascompleted in mid-March 2008. Hardwaredrawings have been completed, and thehardware itself is being fabricated. NASAsLangley Research Center (LaRC) is responsiblefor CM/LAS design and fabrication, installation

and checkout of DFI, plus handling groundsupport equipment (GSE).

Figure 13. The Ares I-X CM/LAS simulatorcompleted its CDR in February 2008.

The CM/LAS structure consists of severalprimary components, including the Orion crewmodule (CM) simulator, the LAS nozzles, thenosecone, and a transition structure between

the mast and the CM known colloquially as aparty hat (Figure 14).


11/31


The GO and CM/LAS teams are workingtogether to ensure hardware integration andoperations in the Vehicle Assembly Building(VAB) once the CM/LAS arrives at KSC inNovember 2008. The LAS Tube segment(Figure 15) is currently being fabricated, as arethe attachments for the simulated motor nozzles.Upon completion of the tube, assembly ofCM/LAS party hat will commence.

Figure 15. The LAS tube section is in themidst of fabrication.

Ground Systems / Ground Operations (GS/GO)

The Ares I-X flight will provide valuableexperience for the KSC Ground Systems andGround Operations teams in integrating,

stacking, and launching Ares I. Most of theground systems to be built for Ares I-X haveundergone a 90 percent review and begunfabrication. Among the activities to be addressedare:

Transporting the vehicle elements toKSC

Loading RoCS propellants in theHypergol Maintenance Facility (HMF)

Processing the vehicle in the ARF and

RPSF Stacking the vehicle in the VAB Conducting vehicle rollout, and launch

and recovery operations.

The USS segments and CM/LAS will beassembled into five stacks and the DFI will betested in VAB High Bay 4. This will includeintegrating the first stage 5

thspacer segment

and forward structures into Stack 1. The FSsegments and the stacks will be integrated inHigh Bay 3. The baseline schedule includes tendays for integrated testing. Closeoutsexceptfor the Lower 5SS door (Ordnance Access)arecompleted prior to rolling to the pad (Figure 16).


12/31


13/31

National Aeronautics and Space Administration

www.nasa.gov

Stephan R. DavisDeputy Mission Manager

2009 International Astronautical Conference

Stephan R. DavisDeputy Mission Manager

2009 International Astronautical Conference

Ares I-X

Flight TestThe Future

Begins Here

Ares I-X

Flight TestThe Future

Begins Here


14/317465.2National Aeronautics and Space Administration

Constellation Manifest

Deliver crew and cargo formissions to InternationalSpace Station (ISS) and to

Moon and beyond

Continuing progress towarddesign, component testing,and early flight testing

Ares I Crew Launch Vehicle Will carry 6 crew to ISS, 4 toMoon

First flight test 2009

Initial Operating Capability 2015

Ares V Cargo Launch Vehicle

Will launch Earth departure stageand Altair lunar lander to lowEarth orbit for lunar missions

Largest launch vehicle ever

designed

Will begin detailed developmentwork in 2011


15/31



Vehicle Overview

Combines proven space flight andsimulated hardware

Space flight hardware includes:

Four-segment solid rocket booster (SpaceShuttle)

Atlas V-based avionics

Roll control system (Peacekeeper)

Separation system (Space Shuttle)

Parachutes deceleration system (SpaceShuttle)

Booster deceleration and tumble motors(Space Shuttle)

Developmental flight instrumentation

Simulator hardware

Upper stage

Orion crew module

Launch abort system

Fifth segment of booster

Simulated FifthSegment

Orion Crew Module/ Launch Abort

System Simulator

Four-segmentMotor

Upper StageSimulator

FirstStage

Avionics (internalthroughout vehicle)

Roll ControlSystem

Separation PlaneFirst StageAvionics Module

(internal)



Ares I-X Flight Test Objectives

P(1) Demonstrate control of a dynamicallysimilar, integrated Ares I/Orion, usingAres I relevant ascent control algorithms

P(2) Perform an in-flight separation/stagingevent between a Ares I-similar First Stageand a representative Upper Stage

P(3) Demonstrate assembly and recovery of

a new Ares I-like First Stage element at KSC

P(4) Demonstrate First Stage separationsequencing, and quantify First Stageatmospheric entry dynamics, and

parachute performance

P(5) Characterize magnitude of integratedvehicle roll torque throughoutFirst Stage flight



Ares I-X Development Flight Test



First Stage

Heritage Hardware

4 Segment Reusable Solid Rocket Motor

(RSRM) w/Nozzle

Thrust Vector Control (TVC)

Flight Termination System (FTS)

Nose Cap w/Thrusters

Booster Separation Motors (BSMs)

Modified Heritage Hardware

Shuttle Derived Avionics

Aft Skirt

New Developments for Ares I-X

Fifth Segment Simulator (5SS)

Forward Skirt (FS)

Forward Skirt Extension (FSE)

Main Parachute Support Structure (MPSS)

Frustum

Ares I Designs

Parachutes

FTS Extension to Aft Segment

Managed at the NASA Marshall Space

Flight Center, Huntsville, AL



Avionics

Primary avionics subsystems:

FSAM (located in First Stage fifthsegment)

Guidance & Control System

Ground Command, Control, andCommunication (GC3)

Managed at the NASA MarshallSpace Flight Center, Huntsville, ALFirst Stage Avionics Module (FSAM) (Lockheed

Martin Space Systems (LMSS))

Atlas V System Integration Lab(SIL) (LMSS)

Ascent Thrust Vector Controller (ATVC)(Honeywell International)

RedundantRate Gyro

(RRGU)

Fault TolerantInertial

Navigation Unit(FTINU)

RedundantRate Gyro

(RRGU)



Avionics Progress

Component(s) Current Status (As Appropriate) Anticipated

Completion/DeliveryATVC CDR completed June 2007 Oct-08

Fabrication under way

FSAM CDR completed April 2008 Oct-08

Flight Software CDR completed March 2008 Mar-09

Test Readiness Review completed April2008

Ground Software (Ground Control,Command, and Communications/GC3)

Formal testing under way Delivery to KSC October 2008Installation in MLP by May 2009

Systems Integration Laboratory

Vehicle Flight Control Testing Ongoing Oct-08Flight Simulation Testing Ongoing May-09

OFI / DFI Sensors and Harnesses Sensors acquired or on order Cable Harnesses

Undergoing Table Top Reviews ascompleted

CM/LAS July 2008

USS October 2008FS October 2008

OFI Harnesses

FS/USS October 2008

Fault Tolerant Inertial Navigation Unit

(FTINU)

Qualification testing complete Delivery to KSC March 2009

Delivered to United Launch Alliance inMarch 2008

SDA Fabrication begun December 2007 Aug-08



Upper Stage Simulator (USS)

USS is a mass and Outer MoldLimit (OML) simulator

Hardware includes:

Interstage (IS) Simulator

Upper Stage (US) Simulator

Spacecraft Adapter (SA) Simulator

Service Module (SM) Simulator

Developed at the NASA Glenn

Research Center, Cleveland, OH

SM

SA

US-7

US-6

US-5

US-4

US-3

US-2

US-1

IS-2

IS-1

USS to CM/LAS Interface

Service Module

Spacecraft Adapter

Ballast

Avionics in US-1 & US-7DFI throughout

Ballast

Internal Access Doorand ECS Service Panel

USS to RoCS Interface

Interstage

USS to FS Interface



USS Internal Access Concept

Provides access from the Frustumto the CM/LAS

Door in the IS-1 segment

Internal access platforms and ladders

Provides Environmental ControlSystem (ECS) ductwork to maintain asafe work temp, air flow andcontrolled humidity

Internal access door

Common accessplatforms with railings

Ballast platform

IS-1 Segment

FS Frustum



Roll Control System (RoCS)

Provides post-launch 90-degree roll

and mitigation against adverse roll

torques

Modular propulsion system housedin the Ares I-X USS Interstage

Proven space hardware harvested

from Peacekeeper 4th Stage

Managed at the NASA Marshall

Space Flight Center, Huntsville, AL



Instrumented for 924 measurements

Thermal

Structures

GNC/Trajectory

Aero

Shock

Cameras strategically located

Data to be retrieved via telemetry and a datarecorder box that is recovered from the FirstStage after flight

Managed at the NASA Langley ResearchCenter, Hampton, VA

Development Flight Instrumentation (DFI) and Video

Camera 3-1

Camera 3-2

Camera 4-1

Camera 3-3

Orion Crew Module/



Orion Crew Module/Launch Abort System (CM/LAS) Simulator

Outer mold limit (OML)

resembles earlier Ares I

design due to flight test

schedule

Developmental flight

instrumentation sensors

will measure

aerodynamic and

acoustic loads

Developed at the NASA

Langley Research Center,

Hampton, VA

Vehicle Assembly Building



Vehicle Assembly Building(VAB) Operations

The Upper Stage Simulator (USS) segments and Orion CrewModule/Launch Abort System (CM/LAS) will be assembledinto stacks and Development Flight Instrumentation (DFI)tested in VAB Hi-Bay 4

The First Stage segments and stacks will be integrated inHi-Bay 3



Hi-Bay 3 Stacks in VAB

LOX Ballast

Stack 1XL/S/SE/Frustrum/IS-1/IS-2

Stack 2US-1

Stack 3US-2/US-3/US-4/US-5

Stack 4US-6/US-7

Stack 5SA/SM/CM/LAS

LH2 Ballast



Pad 39B at NASA Kennedy Space Center, FL

Lightning Mastraised 100ft

Vehiclestabilizationconceptshown


30/31

7465.18National Aeronautics and Space Administration

Summary

Ares I-X is the firstflight of NASAs newConstellation Program

Ares I-X is adevelopmental testflight to supportthe Ares I

Ares I-X is ontrack for 2009 launchdate

For more information,see

http://www.nasa.gov/ares


31/31

Documents

NASA Ares I-X Flight Test plans