Program update February, 2017 - IEEE › rockrivervalley › files › 2017 › ... · Program...

Program updateFebruary, 2017

Unlimited Rights to NASA in accordance with Prime Contract NNJ06TA25C and Subcontract RH6-118203.

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Export Controlled Information: EAR99

•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


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


•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.


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


•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


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


ITL ABCU


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


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….)


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


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…


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.


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


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)


•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


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


Space launch system (SLS)

UTAS supplied (Heritage Shuttle basis)


CAPU

Aux Power

Unit

HydraulicPump

HydraulicFilter

Manifold

.Gas jet modulated spins

turbine

Hydraulic Fluid(100psi)


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”


PSV SCV

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


Program update February, 2017 - IEEE › rockrivervalley › files › 2017 › ... · Program...

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