48
From Alpha to Orion Skip Hatfield Orion CEV Project Manager

Hatfield skip

  • Upload
    nasapmc

  • View
    13.269

  • Download
    1

Embed Size (px)

DESCRIPTION

 

Citation preview

Page 1: Hatfield skip

From Alpha to Orion

Skip HatfieldOrion CEV Project Manager

Page 2: Hatfield skip

January 11, 2007 2

Orion - Crew Exploration Vehicle

• Orion is the next generation crew piloted spacecraft

– Human access to Low Earth Orbit …– … and to the Moon and Mars

• Development will be managed by a diverse government - industry team

– Project Manager located at Johnson– Project Management Office elements at

Johnson, Langley and Glenn– Technical involvement by 9 NASA

Centers– Lockheed Martin Team formally

selected to be the industry partner

Page 3: Hatfield skip

January 11, 2007 3

Heavy LiftLaunch Vehicle

Crew Launch Vehicle

Earth DepartureStage

Orion - Crew Exploration Vehicle

LunarLander

Components of Program Constellation

Page 4: Hatfield skip

January 11, 2007 4

Orion Project Philosophy

• Expect to fly Orion for a generation

• Mission adaptability as exploration evolves

• Invest in safety – “Liftoff to Landing”

• Design for low operations cost – Invest in life cycle efficiency and lowest total ownership cost

• Leverage experienced workforce and industrial capability

Page 5: Hatfield skip

January 11, 2007 5

Approach for Achieving System Adaptability and Flexibility

• “Build-in” flexibility in areas where technologies are mature– Outer Mold Line, vehicle size, primary structure– Propulsion system components – size for margin– Power system– Launch Abort System performance – size for margin

• Design for state-of-the-art where technology is rapidly advancing– Low power equipment– Small size electronic packaging– Commercial software– Software reuse – Open source software– Flexible, state-of-the-art avionics

Flight Critical Processor

Power Supply A

1553 card (2-Ch)

Audio Card

Video Card

Prox Ops / Arbiter

Network Gateway Flash memory

Power Supply B

Backplane I/OConnector area

Discrete & Analog I/O

Interconnect Arbiter Interconnect Arbiter

Serial I/O Comm

Discrete & Analog I/O

1394B card

1553 card (2-ch)

Interconnect Arbiter Interconnect Arbiter

SDC Processor Graphics card

Isolatedinterconnect

betweenFlt-critical andNon-Flt-critical

processingpartitions

SM OME and RCS

Page 6: Hatfield skip

January 11, 2007 6

Orion Leverages Flight Certified Technologies & Innovations

• Architecture– Spacecraft Survivability Methodology– Open Architecture Systems– Block Upgrade Approach for Lunar System Development– Passive & Active Launch Abort System– Modularity Approach– P3I, Continuous Process Improvements– ICE/IDE & Tools

• Avionics Systems– State-of-the-Art Fifth-Generation Fault-Tolerant Commercial

Aircraft Avionics (787 heritage)– Star Tracker, Rendezvous & Proximity Operation Systems– 6-DOF Sensors– Solar Panels, Electrical Systems & Batteries

• Structures– TPS & Analytical Tools – Friction Stir Welding, Al-Li– Composites in SoA Applications (JSF Experience)

• Propulsion– Non-toxic (CM) Propellants– SMME Approach

787 Avionics

Friction Stir WeldedOrthogridAl-Li

JSF Composite Materials & Manufacturing

Phoenix Solar Array & TPS

Page 7: Hatfield skip

January 11, 2007 7

Project Orion is Leveraging Unique Skills Throughout NASA

Dryden• Lead Abort Flight

Test Integ/Ops• Abort Test Booster

procurement• Flight Test Article

Devt/Integ

Ames• Lead Thermal Protection System ADP• Aero-Aerothermal database• Software and GN&C support

JPL• Thermal Protection

System support

Johnson• Lead Crew Module integration• Orion Spacecraft Integration• GFE projects management• Flight Test Program

Kennedy• Ground processing• Launch operations• Recovery operations

Langley• Lead Launch Abort

System integration• Lead landing system ADP• SE&I Support

Marshall• LAS and SM SE&I Support

Glenn• Lead Service Module and

Spacecraft Adapter integration• Flight Test Article “Pathfinder”

fabrication• SE&I Support Goddard

• Communications Support

Orion Project Management

Page 8: Hatfield skip

January 11, 2007 8

Orion Lockheed Martin Industry Team

KSC• Final Assembly• Checkout• Acceptance Test• Sustaining Engineering• Spacecraft Refurbishment

LM LaRC• LAS Liaison Office

• Launch Abort System• Safety & Mission

Assurance

• Systems & Design Engineering Support

• Program Management• Systems Integration• Crew Module Development• Service Module Development• Qualification Test• Software Development

Michoud • CM and SM

Structures

LM GRC• SM Liaison Office

• Avionics• Integrated System

Health Management• Crew Interface• Mission Ground Ops Support

• Propulsion

• Operator Interfaces• Ground Processing• Mission Flight Planning• Software Development

• Environmental Control & Life Support• Active Thermal Control• System Power Management

Page 9: Hatfield skip

January 11, 2007 9

Decision Making Structure

LM ProgReview

Board (PRB)

CPCB

SR&QA Panel

Lock

heed

Led

Rev

iew

s

CEV RiskMgmtPanel

LM Eng Review

Board (ERB)

T&V IntegPanel

FT Panel

FTA WG

NA

SA Led R

eviews

NASA CAM/org/panel communication and issue/position coordination before ERB/PRB

Level IIBoards

Level I Boards

Orion Project

Constellation Program

PM (Cost/Sched/Tech)AccountabilityNASA Issue

CoordTech Integration

Communication

Communication with NASA orgs and/or panels

GEM Panel

LM/NASAIPTs/SPTs/IWGs

LM “Tabletop”

Reviews

CEV IntegPanel

Ops IntegWG

CockpitWG

GFE/ADPProjects

Page 10: Hatfield skip

January 11, 2007 10

AdministratorOCE

JSC CenterDirector

JSC EngDirector

CEV CE

Contractor CE

Contractor PM

AA

Cx ProgramManager

CEV ProjectManager

Cx CE

LAS PLE

SM PLE

SM CAM

LAS CAM

LaRC CenterDirector

LaRC EngDirector

All module Issues will be “Passed Through” CEV CEIf CEV CE and module PLE disagree,then TA proceeds up parallel Center Chains

If JSC/module Eng disagree then goes to CDIf JSC/module Center Directors disagree thengoes up to OCE

GRC CenterDirector

GRC EngDirector

Independent Technical Authority is Adapted to the Orion-CEV Management Strategy

Page 11: Hatfield skip

January 11, 2007 11

Functional Integration Teams

Functional Integration Teams

Functional Integration TeamsIWGIWGIWG

IPTIPTIPT

Proposed Joint LM-NASA Decision Structure:Decision protocol within contract scope

Subsystem Product Teams

“Tabletop”Reviews

Integrated Product Teams

Integration Working Groups

PRB

ERB

Horizontal Integration

Formal Decision Process

NASA GFE/ADPProjects

• Verify Horizontal integration complete• Management Review

• Technical baseline control

• Contract baseline control

Page 12: Hatfield skip

January 11, 2007 12

Orion Team Refining Requirements and Design Systematically

2006

Feb Mar June

CEV MajorMilestones

Jan April May July Aug Sept

CEVAnalysisCycles

CxPSRR

Phase 2ATP

Oct Nov Dec

CEV SRRData Drop

“605” Config

Aug Sept Oct Nov Dec

2005

Jan Feb2007

CEV SRR(Board)

Phase 1ATP

CxPICPR

Draft SRD Release CFI

CEV Arch Changes

RAC-2

Face-to-Face

RAC-3CRC-1

CICP Approval

CRC-1A

CRC-2

CEV-CLV DAC Outbrief

RAC-1

CRC-3CRC-1

CRC-1A

CRC-2

CRC-3

RAC = Requirements Analysis Cycle CRC = CEV Reference Configuration

NASA – LM TeamNASA – LM Team

NASA-LM Reconciled

Configuration

501 LM 503 LM 504601 602 LM 603 LM 604

LM 502

606

DAC1

Page 13: Hatfield skip

January 11, 2007 13

Orion System Elements

Spacecraft Adapter –structural transition to launch vehicle

Orion consists of four functional modules

Launch Abort System --emergency escape during launch

Crew Module –crew and cargo transport

Service Module –propulsion, electrical power, fluids storage

Page 14: Hatfield skip

January 11, 2007 14

Converging the designs

• Post-award integration involved maturation of requirements and reconciliation of design differences between the NASA CRC3 and LM 604 vehicle configurations.

• 605 did not close on all requirements – i.e. control masses.• Category 1 action assigned from 605 ERB to conduct a Pre-

DAC1 requirements and weight summit and form a joint integration panel.– Identify opportunities for design solution and requirements

changes that will close 606 Point of Departure configuration.

CRC-3 604

Page 15: Hatfield skip

January 11, 2007 15

Orion Spacecraft General Arrangement

Mission SummaryNo. Crew 4 (lunar), 6 (ISS)Crewed Mission Duration 18 days (lunar)Quiescent Duration 210 daysTotal ΔV 5864 ft/s

Configuration SummaryDiameter (CM & SM) 16.5 ftPressurized Volume (Total) 691.8 ft3

Habitable Volume (Net) 342 ft3

SM Propellant MMH/N2O4CM Propellant GO2/GCH4Payload (Lunar Return) 220 lbs

Block 2 Mass Properties SummaryGLOW 61,860 lbEMO (1/8 LAS Partial) 50,231 lb

Mission SummaryNo. Crew 4 (lunar), 6 (ISS)Crewed Mission Duration 18 days (lunar)Quiescent Duration 210 daysTotal ΔV 5864 ft/s

Configuration SummaryDiameter (CM & SM) 16.5 ftPressurized Volume (Total) 691.8 ft3

Habitable Volume (Net) 342 ft3

SM Propellant MMH/N2O4CM Propellant GO2/GCH4Payload (Lunar Return) 220 lbs

Block 2 Mass Properties SummaryGLOW 61,860 lbEMO (1/8 LAS Partial) 50,231 lb

SMCM

LAS

Page 16: Hatfield skip

January 11, 2007 16

Launch Abort System Summary

Launch Abort Vehicle (LAV): Crew Module + LAS

Nose Cone

Attitude Control Motor(Eight Nozzles)

Canard Section(Stowed Configuration)

Jettison Motor(Four Aft, Scarfed Nozzles)

Interstage

Abort Motor(Four Exposed, Reverse Flow Nozzles)

Adapter Cone

Boost Protective Cover (BPC)

Crew Module (CM)

Configuration SummaryAbort MotorNo. of Nozzles: 4Nozzle Cant Angle (to CL): 25ºIsp (sea level): 250 sThrust (Total in Vehicle Axis; vac.): 518,670 lbfBurn Time: 4.0 sAttitude Control MotorNo. of Nozzles: 8Nozzle Cant Angle (to CL): 90ºIsp (vac): 227sThrust (per Nozzle; vac.): 3,000 lbfBurn Time: 20 sJettison MotorNo. of Nozzles: 4Nozzle Cant Angle (to CL): 35ºIsp (vac.): 221 sThrust (Total in Vehicle Axis; vac.): 40,975 lbfBurn Time: 1.5 s

Mass Properties SummaryDry Mass 8,184 lbsPropellant 5,546 lbsGLOW 14,428 lbs

Configuration SummaryAbort MotorNo. of Nozzles: 4Nozzle Cant Angle (to CL): 25ºIsp (sea level): 250 sThrust (Total in Vehicle Axis; vac.): 518,670 lbfBurn Time: 4.0 sAttitude Control MotorNo. of Nozzles: 8Nozzle Cant Angle (to CL): 90ºIsp (vac): 227sThrust (per Nozzle; vac.): 3,000 lbfBurn Time: 20 sJettison MotorNo. of Nozzles: 4Nozzle Cant Angle (to CL): 35ºIsp (vac.): 221 sThrust (Total in Vehicle Axis; vac.): 40,975 lbfBurn Time: 1.5 s

Mass Properties SummaryDry Mass 8,184 lbsPropellant 5,546 lbsGLOW 14,428 lbs

Page 17: Hatfield skip

January 11, 2007 17

Launch Abort Sequence

Attitude Control Motor Reorientation for LAS Jettison

LAS Jettison From CM

LAS Abort & Attitude Control Motors Ignited

CM DrogueDeployment

LAS pulling CM safely free of CLV during abort

Page 18: Hatfield skip

January 11, 2007 18

LAS Control Motor Description

Nozzles Located Radially

Thermal Batteries & Electronics

Redundant Thermal

Batteries and Electronics

Titanium Plenum

Composite Case

Carbon-SiC Pintle & Throat

1) To Nose Cone: Common Attach Ring, Bolted2) To Interstage: Common Attach Ring, Bolted3) To Raceway: Bolted Interface

Interfaces

0 to 100% ThrustThrottle Capability

AAB-3751Propellant Grain

Two Thermal BatteriesPower

Every 45° Starting at ZeroNozzle Positions

0.035” ABL-5 Cork Bonded 0.01” RTVSurface Thermal Protection

LAV Pitch & Yaw Control Function

3,000 lbfMaximum Thrust (Vacuum) Per Nozzle

40 inMotor Length

32 inMotor Diameter

477 / 622 lbmMotor Weight (Inert / Propellant) (w/WGA)

< 0.05 sec to 90% ThrustResponse Rate @ MEOP

227 secIsp (Nozzle Center Line, Sea Level)

90 degThrust Axis (from LAS Center Line)

8# Nozzles

20 secBurn Time

7,000 lbfMaximum Thrust (Vacuum) in Any Axis

LAS Control Motor [Rev.-R]

Page 19: Hatfield skip

January 11, 2007 19

LAS Abort Motor Description

Igniter Assembly

Propellant DL-H503

Graphite Composite Case

Steel Nozzle Assembly

1) To Interstage: Common Attach Ring, Bolted2) To Adapter Cone: Bolted3) To Raceway: Bolted Interface

Interfaces

150 millisecRamp Up to 90% Thrust

2 degThrust Axial Alignment

1,750 psiMEOP

DL-H503; 6% AlPropellant Grain

0.14” ABL-5 Cork Bonded 0.01” RTV

Surface Thermal Protection

Provides Abort ImpulseFunction

3479 / 4581 lbmMotor Weight (Inert / Propellant) (w/WGA)

36 inMotor Diameter

216 inMotor Length

4 Reverse Flow, Exposed

Nozzle Type / #

25 degNozzle Cant Angle

255 secIsp (Nozzle Center Line, Sea Level)

> 4.0 secBurn Time

518,670 lbf, 70° FMaximum Total Axial Thrust (Vacuum)

LAS Abort Motor [Rev.-R]

Nozzle Manifold

Flow Deflector

Page 20: Hatfield skip

January 11, 2007 20

LAS Adapter Cone Description

LaunchCable or Linkage Attachments to Base of Mechanism

1) To Abort Motor: Bolted2) To Crew Module: Six Point Attachment3) To BPC: Counter Sunk Fasteners4) To LIDS or APAS or APAS/LIDS: Three Cables or Rigid Linkages

Interfaces

Bolts & Bolt ExtractorsSeparation Mechanism

106 inTotal Length

6-Point Physical Interface Between LAS & CM; Carries Abort Loads

Function

1799 lbmWeight (w/WGA)

0.12” ABL-5 Cork Bonded 0.01” RTVThermal Protection

M55J / 977 Graphite / EpoxyAdapter Structure

15-5PH Stainless SteelAdapter Rings / Feet

LAS Adapter Cone [Rev.-R]Gr / Ep

Monocoque Structure

Stainless Steel Rings

and Feet

Removable sep-nut

access panels

Adapter extension

AbortMechanism Pyro Separation from CM

NominalCables or Linkages Are Severed Disconnecting LAS from Mechanism

Page 21: Hatfield skip

January 11, 2007 21

NESC Alternate LAS Phase 2 (1/2)• CLV Stack Aerodynamic

Performance – Phase 1 axisymetric CFD indicated an effective

mass-to-orbit increase of 1,000 lbs for an idealized LAS aerodynamic shape

– Plan stack wind tunnel testing in Boeing Polysonic Tunnel (Completion: 30 Jan)

– Trajectory analysis will quantify mass-to-orbit benefits (Prelim Results: 15 Feb; Final Results: 15 April)

604 mod 6Baseline

ExposedNozzleALASIntegrated Nozzle

ALAS

ALAS Geometry Variations

• CEV Aeroacoustic Performance– Analytical quantification of ALAS improvement

of aerodynamic noise source on CM and SM as compared to baseline LAS geometry (LM Draft: 21 Dec; Prelim: 15 Feb; Final: 15 April)

– Plan acoustic measurements on ALAS in Ames UPWT (piggyback on planned acoustic test 16-AA) (Completion: 30 April)

~170dB

~170dB

ALAS w/scarfedNozzles

~147dB

~149dB

BaselineLAS

Page 22: Hatfield skip

January 11, 2007 22

Orion Spacecraft Crew Module

Configuration SummaryDiameter 16.5 ftRef Hypersonic Lift to Drag Ratio .34 @ 157°αPressurized Volume (Total) 691.8 ft3

Habitable Volume (Net) 342 ft3

Habitable Volume per 4 CM 85.4 ft3

CM Propellant GO2/GCH4Total CM Delta V 164 ft/sRCS Engine Thrust 160 lbfLunar Return Payload 220 lbs

Mass Properties SummaryDry Mass 17,396.8 lbsPropellant Mass 385.1 lbsOxygen / Nitrogen Mass / Water 282.8 lbsCM Landing Wt. 16,174.3 lbs GLOW 18,900 lbs

Configuration SummaryDiameter 16.5 ftRef Hypersonic Lift to Drag Ratio .34 @ 157°αPressurized Volume (Total) 691.8 ft3

Habitable Volume (Net) 342 ft3

Habitable Volume per 4 CM 85.4 ft3

CM Propellant GO2/GCH4Total CM Delta V 164 ft/sRCS Engine Thrust 160 lbfLunar Return Payload 220 lbs

Mass Properties SummaryDry Mass 17,396.8 lbsPropellant Mass 385.1 lbsOxygen / Nitrogen Mass / Water 282.8 lbsCM Landing Wt. 16,174.3 lbs GLOW 18,900 lbs

Pitch thrusters

2PL

Yaw thrusters

2PL

Roll thrusters

2PL

Docking windows 2PL

Horizon windows 2PL

Forward bay accesspanels 6PL

Lower backshell Panels 5PL

Hatch

SLA-561V backshell TPS AZ93 coating

PICA Heatshield, ML-440WSO Coating

Drogue deploymenthatch for Fwd baycover jettison

Main Parachutes (3)

Drogue mortarsparallel deploy (2)

8 inches seat stroke (x, y, z)

Avionics bays

ECLSSBay

99% MaleUnpressurized

3% spinal growthMain deployment pilot chutes (3) WMS

(toilet)

1% Female

Page 23: Hatfield skip

January 11, 2007 23

Docking Hatch

CM Configuration Overview

Side Window

Side Hatch

Forward Window Docking

Tunnel

Backplane Stowage

Page 24: Hatfield skip

January 11, 2007 24

Aft Bay Configuration

Added Phase-Change Heat Exchangers

(2 plcs)

Deleted ATCS Freon Tanks and Manifolds (4 items)

Added Horizontal Retro Rockets (4 plcs)

Added Vertical Retro Rockets (4 plcs)

Relocated 1 RCS GOX Tank

Relocated 1 RCS CH4 Tank

Deleted Fourth Thruster String(5 plcs)Changed to 160lb Thrusters (15 plcs)

Swapped 1:00. 3:00, 9:00 and 11:00 Wedges to Match Hatch Swap to –Y

Reformatted Backup Landing Battery

Resized RCS Tankage for Increased Residuals(8 plcs)

Rearranged Batteries, Split Cold Plates(6 plcs)

Note Interferences with PCS Tankage, ATCS Exchangers, and Horizontal Retros

Page 25: Hatfield skip

January 11, 2007 25

Hard Lockers (Provide solid footing for crew ingress/egress thru hatch)

Late stowage areas(Near hatch and not underneath seated crew)

Avionics(Redundant strings physically

separated & accessible on orbit. Spacing accommodates cable bends. Orientation eliminates

blind connectors.)

ECLSS(Co-located with avionics in floor for shorter cable lengths & improved CM C.G.)

Galley(Physically separate from WMS)

Operator 1 and 2(Position provides forward view for docking and view of horizon during ascent & entry)

Block 1A Configuration

Crew Cabin Configuration (Block 2)

Page 26: Hatfield skip

January 11, 2007 26

10 Generic Emergency Re-entry Switches

Emergency Re-entry Initiation, Pyro Inhibits, ECLSS mode

Keyboard

ECLSS umbilical

Main Caution and Warning Lights(2 sets)

Communications

Center Display Controls

Temperature Control

Cabin Lights Pilot Display Controls

Commander Display Controls

Fire Suppression Holes

1310 Displays (x3)

EPS Inhibits - Breakers

Crew Console

Page 27: Hatfield skip

January 11, 2007 27

Heatshield and Crushable Structure

JettisonHeat shield

Crushable Core w/ Face Sheets: (~7 ft/s)• light blue 3” thk Core, 0.020” face

sheets

• dark blue 1” thk, 0.010” face sheets

Core support frame

Backshell

New stiffenerson Pressure Volume

Page 28: Hatfield skip

January 11, 2007 28

LIDS Interface

LIDS-GFE

LID Attachment Ring

LID AvionicsWire Routing

LID Attachment Ring

Page 29: Hatfield skip

January 11, 2007 29

Orion Spacecraft Service Module

Configuration SummaryStructural Configuration 3 Rings

6 LongeronsPropulsion Configuration 2x2 Serial FeedSM Propellant MMH/N2O4Total SM ΔV 5700 ft/sMain Engine Thrust 7500 lbfRCS Thruster Thrust 25 & 125 lbfSolar Array Area 388 ft2

Solar Array Power 9.15 KwRadiator Area 310 ft2

Configuration SummaryStructural Configuration 3 Rings

6 LongeronsPropulsion Configuration 2x2 Serial FeedSM Propellant MMH/N2O4Total SM ΔV 5700 ft/sMain Engine Thrust 7500 lbfRCS Thruster Thrust 25 & 125 lbfSolar Array Area 388 ft2

Solar Array Power 9.15 KwRadiator Area 310 ft2

Lunar Science Payload

Umbilical Housing

High Gain Antenna

Systems Access Panels(2 PL)

MMOD Blanket(Protect Engine)

OME Engine(7500 lbf (vac))

RCS Thruster Pods (4 PL)Each Pod: 6 Thrusters (25lbf (vac))TEI Backup (+X Engines) (4PL)Each Pod: 2 Thrusters (125lbf (vac))

Radiator Panel(301 ft2 Radiating Area)

Ultra-Flex (Mid-Deploy)

Ultra-Flex (Fully Deployed

Ultra-flex Solar Array(388 ft2 Generating Area)

TEI Backup (+X Engines)R4D 125lbf, radiation cooled

RCS Thruster PodBlock Swap GeometryR1E 25lbf, radiation cooled

RCS & TEI Backup

(Four Places)

Page 30: Hatfield skip

January 11, 2007 30

Alternate Service Module/Spacecraft Adapter

• Technical trade studies by NASA and LM identified that an encapsulated SM offered mass savings between SM and SA

• CEV Weight Reduction Team approved trade on 18 Dec

• Alternate SM/SA Benefits– Fairing jettisons after aero loads

diminish– Reduction of aero thermal loads on

radiators (w/ insertion orbit changes)– Improved packaging solutions (e.g.

arrays)– Protected environment at pad– Avionics / ECLS Ring provides

modularity to improve integration & test

• Team investigating two implementations of concept

• Ongoing results continue to show significant mass savings

• Final results to be presented at LM engineering review board on 6 Feb

Tasks

SM Primary Structure CAD Model Available

Populate Model w/Subsys

CAD Model Available for Subsys Review & Analysis

Model Rvw w/GRC & MSFC

Subsystem Analysis Cycle

FEM Development

Tabletop Preps

Tabletop Review

ERB Preps

Feasibility (Go-No Go) ERB

Final Summit Outbrief

Week of 1/7

1/9 Avionics ring

1/25

2/1-2

1/15

January

Week of 1/14 Week of 1/21 Week of 1/28

Design feedback, MEL’s available

1st resize complete Primary structure

mass props

1/29

1/11 Prop module/SA

1/161/22

Externallongerons

or truss)

SA Interface

Internal LongeronConfig (ILC)

External LongeronConfig (ELC)

Internal longerons

SA Interface

Page 31: Hatfield skip

January 11, 2007 31

Nominal Ascent Sequence

Encapsulated SM (External Longeron)

Fairing Separation (2 Panels)4 – FLSC2 – Thrust Rails

Fairing Jettison

Press to MECOLongeron Separation4 – Frangible Bolts4 – Gas Thrusters4 – Hinged Longerons

Page 32: Hatfield skip

January 11, 2007 32

Major NASA Technology Applications to Meet the Mission

.

TPS “Heat Shield” Landing Impact AttenuationParachutes

Docking Systems

Pre-EntryInitial

Pull-Up

Controlled Climb to

Atmospheric Exit Ballistic Skip

Final Glide

LandingSite

Edge of Atmosphere

8

Final WX Update

TD-3 hrs

Skip Reentry Automated Rendezvous

& Docking Aero Sciences

Page 33: Hatfield skip

January 11, 2007 33

Thermal Protection System Advanced Development Project (ADP)

• Purpose is select the best overall performing material for the Crew Module heat shield– Lunar return conditions (Block II) is primary focus

• Mitigation plan is to develop materials for ISS return conditions (Block I) if the lunar solution cannot be developed in time

– Includes thermal performance, structural and materials properties and manufacturability to the 198 in diameter

• Managed by the Ames Research Center• Phase I – Lunar Return (Block II)

– Select up to 5 materials for initial investigation of material properties for suitablility - Complete

• Phase II – Lunar Return– Boeing/FMI team selected to produce PICA heatshield– Larger coupon testing slated to start late January

• Block 1 Heatshield (LEO only) back-upcontract in work for SLA material

Heat shield

Back shell

Page 34: Hatfield skip

January 11, 2007 34

TPS Advanced Development

Ablative TPS Development Test in an ArcjetAVCO technicians injecting ablator into honeycomb(CM had 300,000 cells)

Goal: reduce uncertainty levels by validation with flight data

Page 35: Hatfield skip

January 11, 2007 35

CEV Aerosciences Project

On-Orbit Plumes

Environment

Pad Abort

Transonic, SupersonicHigh Q, High Drag Abort

Mach 0.9 to 4, 30k to 150k ft alt

Hypersonic Abort

CEV LEO Direct orBallistic Reference Entries

LAT SepAt 25k ft

Parachute Cover Sep

Parachute System Deploy

Lockheed design has retro rockets

Entry Heating Phase

Service Module Jettison

Service Module Jettison

LAT Sep for high altitude LAS abort

Plume Heating

CEV Lunar Direct, Skip, or Ballistic

Reference Entries

Turn-around maneuver

Mach40

Mach 25

Mach ~0.5Recovery SystemsDeploy

Main ChutesMach ~0.1

Service Module Jettison

LAT Nominal JettisonMach ~7.5, ~200k ft alt

Ascent Abort Separation

Environment

Atmospheric Entry Environment

CSM droop

LAV uses canards to stabilize vehicle

Page 36: Hatfield skip

January 11, 2007 36

Low Impact Docking System (LIDS)

• Background– LIDS has been in advanced development since approximately 1996– Baselined to have flight hardware complete in 2010– To be used on first CEV launch to ISS with an APAS adapter– Fully androgynous system with both soft and hard capture

features• Soft capture uses electromagnetic • Hard capture uses hooks

Page 37: Hatfield skip

January 11, 2007 37

Active LIDS vs. Proposed Passive LIDS for Adapter

Active LIDS• All passive functions plus:

– Fully Androgynous– 6-DOF Soft Capture Platform– Electromagnets (soft capture)– Latches (hard capture)– Primary/secondary latch drives– Pyro sep system– Push-off system for sep– Seals

• Avionics boxes

Passive LIDS for Adapter• Passive functions

– Soft capture ring• Guide Petals• Magnetic striker plates

– Latch tabs (passive hooks)– Umbilical connectors and cables

• Custom LIDS tunnel interfaces to APAS• Static structure to support soft capture

ring

Page 38: Hatfield skip

January 11, 2007 38

ISS LIDS/APAS Adapter

APAS

APAS

Act

ive

LID

S

ATLAS

Pas

sive

LI

DS

Crew Module

PMA Node

ISS CCA

Power Converter

APASAvionics

120V Power

Docking Target(s)

VMC

S-band System

1394

ISS MDM

GN&C

Navigation Sensor(s)

1553

MBSU

28vdc

• Orion will dock to ISS via existing APAS mechanisms, leaving adapter for LIDS on subsequent missions

Page 39: Hatfield skip

January 11, 2007 39

Propulsion Isolation ValveAdvanced Development

Developing a low mass, variable speed propellant isolation valve– Surge pressure (waterhammer)

control– 28 VDC bus voltage– Scalable to other applications

(variable regulator, main engine isolation)

– Originally for LOX/CH4, also candidate for MMH/N2O4 service

S

S SS

S S

SS

P

He He

S

S P

M

M

M

M

M

M

S

S

SS

S S

S

S

S

S

S

S

S

S

S

S

S S

SS

S

S

S

S

S

S

S

S

S

SS

S

S

S

SS

S S

S

S

S

S

S

S

S

S

S

S

S S

SS

S

S

S

S

S

S

S

S

S

SS

S

S

S

SS

S S

S

S

S

S

S

S

S

S

S

S

S S

SS

S

S

S

S

S

S

S

S

S

SS

S

S

S

SS

S S

S

S

S

S

S

S

S

S

S

S

S S

SS

S

S

S

S

S

S

S

S

S

SS

S

Thruster Pod 1 Thruster Pod 2 Thruster Pod 3 Thruster Pod 4

C E E

D A C

A C D

E D A

A C A

E D E

C E C

D A E

DAC2 case 4 (parallel)

MMH

PMD

MMH

PMD

MM M M

S

S

S

S

NTO

PMD

NTO

PMD

S

S

S

S

M

M

MM M M

M

M

Page 40: Hatfield skip

January 11, 2007 40

Cryogenic Visor Valve Operation

Page 41: Hatfield skip

January 11, 2007 41

UNDER REVIEW

Orion Flight Schedule OverviewFY06

SRR

Project RequirementsPrime Award

CDR

SDR

PDR

Development / QualTesting

Flight Article Production

First Human Launch10/2013

Project Design

Integrated ARES-Orion Launches

FY07 FY08 FY09 FY10 FY11 FY12 FY13 FY14 FY15

Transonic Abort

Max qNom Abort

Devt. LASPA

Proto LAS PA

Ares I-XFT

(1st stage test)

Orion/Ares 1Hi Alt Abort

Orion/Ares 2OrbitFlight

Max qOff-Nom Abort

Page 42: Hatfield skip

January 11, 2007 42

Flight Test Program -- Progress Toward First Flight

• Formally approved the agreement with USAF to develop the Abort Test Boosters (ATB) for the Flight Test Program

• Committed to first flight test in late 2008

Page 43: Hatfield skip

January 11, 2007 43

CAP Aerosciences - Testing and Development Facilities

Ames UPWT (11’ & 9’x7’)

Langley UPWT (4’x4’ high and low) and Mach 10

Langley TDT (16’)

AEDC Hypersonic Tunnels B, C, 9

Aberdeen Proving Grounds

Ames Range Complex: EAST, HFFAF, GDF

Langley Hypersonic ComplexMach 6 Air, Mach 6 CF4, others

CUBRC LENS I, LENS II, LENS-X

NASA “Columbia” Supercomputing Facility

Page 44: Hatfield skip

January 11, 2007 44

Orion Production Infrastructure is Coming On-Line!

• KSC / Operations & Checkout Building

– Highbay for all CEV final assembly

– Highbay cleanout underway– Handover completed on 30 Jan

2007

Page 45: Hatfield skip

January 11, 2007 45

4

Crew Exploration Vehicle

Export Controlled InformationPMR #2 Draft

CEV Bldg 103 Manufacturing Area

Alt 1

NOWAlt 2

Proposal

MAF Use Working Group Area Offered

ORION Operations at Michoud Assembly Facility

Detailed Area

Layout

MAF

Page 46: Hatfield skip

January 11, 2007 46

CEV Vehicle-Level Qualification Test Facilities

• Baseline to use LM Denver facilities• Contingent on ability to reduce

predicted acoustic vibration levels for CEV during flight

– ALAS activity– 6 months to complete wind

tunnel testing and further design assessments

– GRC SPF option as a backup• Develop capabilities in parallel for 6

months

Page 47: Hatfield skip

January 11, 2007 47

CEV Avionics Integration Laboratory (CAIL)Facility Status

• CAIL is key avionics and software integration for development and mission support

• Government facility located at Johnson Space Center• New build facility

Page 48: Hatfield skip

January 11, 2007 4848

Orion Advances the Human Exploration Vision

• Orion is the next generation crew piloted spacecraft

– Human access to Low Earth Orbit …– … and to the Moon and Mars

• Orion has a talented management team and workforce which utilizes unique personnel and facility strengths from across NASA and industry

• We have an exciting path to bring Orion to meet the mission

– Finalize requirements– Mature the technology– Design the Systems and Modules– Produce the hardware and software– Test the Systems– Prepare for first flight operations

• We are committed to meeting the national priorities for Orion!