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From Alpha to Orion
Skip HatfieldOrion CEV Project Manager
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
January 11, 2007 3
Heavy LiftLaunch Vehicle
Crew Launch Vehicle
Earth DepartureStage
Orion - Crew Exploration Vehicle
LunarLander
Components of Program Constellation
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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]
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
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
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
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
January 11, 2007 23
Docking Hatch
CM Configuration Overview
Side Window
Side Hatch
Forward Window Docking
Tunnel
Backplane Stowage
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
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)
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
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
January 11, 2007 28
LIDS Interface
LIDS-GFE
LID Attachment Ring
LID AvionicsWire Routing
LID Attachment Ring
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)
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
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
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
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
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
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
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
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
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
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
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M
M
S
S
SS
S S
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S
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S
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S
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SS
S
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S
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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
January 11, 2007 40
Cryogenic Visor Valve Operation
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
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
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
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
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
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
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
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!