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Mo de lling o f Pro pe lla nt Ma na g e me nt Syste ms in E a rly-Pha se L a unc he r De ve lo pme nt E UCASS 2015 Va ne ssa Cla rk Ge rma n Ae rospa c e Ce nte r I nstitute o f Spa c e Syste ms Spa c e L a unc he r Syste m Ana

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SLIDE 1

Ge rma n Ae rospa c e Ce nte r

I nstitute o f Spa c e Syste ms Spa c e L a unc he r Syste m Ana lysis L inze r Str. 1 28359 Bre me n Ge rma ny

E UCASS 2015

Mo de lling o f Pro pe lla nt Ma na g e me nt Syste ms in E a rly-Pha se L a unc he r De ve lo pme nt

Va ne ssa Cla rk

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SLIDE 2

Co nte nts

www.DL R.de / SART

  • Cha rt 2
  • I

ntro duc tio n

  • PMP Mo de lling Appro a c h
  • Sa turn-V a nd AS506
  • Ve hic le Ove rvie w
  • Missio n Ove rvie w
  • Sizing Re sults
  • L

a yo ut

  • Ulla g e E

vo lutio n a nd NPSP

  • Co nc lusio n a nd Re c o mme nda tio ns

> PMP > Va ne ssa Cla rk • E UCASS > 01.07.2015

So urc e : NASA

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SLIDE 3

I ntro duc tio n

www.DL R.de / SART

  • Cha rt 3

> PMP > Va ne ssa Cla rk • E UCASS > 01.07.2015

Motivation

Cryo g e nic Sta g e s

  • Hig h spe c ific impulse ; inc re a se pa ylo a d ma ss

Cryo g e nic ta nks: c ritic a l te c hno lo g ie s

  • T

ypic a l inte g ra l struc tura l ro le ; la rg e influe nc e o n o ve ra ll de sig n

Pro pe lla nt ma na g e me nt

  • Cruc ia l func tio na l ro le ; hig hly se nsitive

Sa turn-V:

  • We a lth o f sta g e a nd flig ht da ta (e .g . AS506)
  • Simila r ye t hig hly c o mple x syste m

So urc e : NASA So urc e : NASA

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SLIDE 4

I ntro duc tio n

www.DL R.de / SART

  • Cha rt 4

> PMP > Va ne ssa Cla rk • E UCASS > 01.07.2015

Propellant Storage and Management Mass Tanks Cylinders Domes Baffles Y-Rings, Manholes Lines Feedlines Fill and Drain Lines Pressurisation Lines Valves and Regulators Pressurant Gas Storage Pressurant Gas Tanks Heaters, heat exchangers Thermal Management Thermal Insultation

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SLIDE 5

I ntro duc tio n

www.DL R.de / SART

  • Cha rt 5

> PMP > Va ne ssa Cla rk • E UCASS > 01.07.2015

Spac e T r anspor tation Syste m (ST S) Pr e liminar y De sign

DL R-SART T

  • o l b o x ha s b e e n de ve lo pe d fo r pre limina ry spa c e

tra nspo rta tio n syste m a na lysis a nd de sig n:

  • F

a st c o mputa tio n time (se c o nds, minute s); mo de lling (minute s, fe w

ho urs)

  • Simple
  • F

le xible

  • Re lia ble
  • Modula r

Co nfig ura tio n a nd ma ss T he rma l Struc ture F lig ht dyna mic s a nd c o ntro l Ae ro dyna mic s Pro pulsio n T ra je c to ry Sub syste ms

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SLIDE 6

I ntro duc tio n

www.DL R.de / SART

  • Cha rt 6

> PMP > Va ne ssa Cla rk • E UCASS > 01.07.2015

Co nfig ura tio n a nd Ma ss Pro pulsio n Ae ro d yna mic T ra je c to ry T he rma l Co ntro l Struc ture s Sub syste ms

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SLIDE 7

I ntro duc tio n

www.DL R.de / SART

  • Cha rt 7

> PMP > Va ne ssa Cla rk • E UCASS > 01.07.2015

Co nfig ura tio n a nd Ma ss Pro pulsio n Ae ro d yna mic T ra je c to ry T he rma l Co ntro l Struc ture s Sub syste ms T he rma l he a t flux L

  • a d s, e nviro nme nta l c o nd itio ns

E ig e nfre q ue nc ie s Ne w struc tura l ma ss Re q uire d ta nk vo lume s E ng ine re q uire me nts, ma ss flo w ra te s, mixture ra tio s

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SLIDE 8

PMP Mo de lling Appro a c h

www.DL R.de / SART

  • Cha rt 8

> PMP > Va ne ssa Cla rk • E UCASS > 01.07.2015

Pr

  • gr

am F unc tion

  • Ra pid sizing a nd la yo ut o f ta nks (le ng th,

ma ss, thic kne ss) a nd line s (ma ss)

  • T

he la yo ut o f the pre ssurisa tio n syste m:

  • Simula tio n o f the e ntire missio n, inc luding

sta g e lo a ds, the rma l lo a ds, e ng ine o pe ra tio n a nd the lo g ic a l c o ntro l o f the ulla g e pre ssure s, inc luding b o th pre ssura nt g a s inje c tio n a nd ve nting .

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SLIDE 9

www.DL R.de / SART

  • Cha rt 9

> PMP > Va ne ssa Cla rk • E UCASS > 01.07.2015

PMP Mo de lling Appro a c h

Mode ls

  • T

he c a lc ula tio n me tho ds e mplo ye d in the pro g ra m a re 1-dime nsio na l, a nd invo lve inte g ra l c o nside ra tio n o f c o ntro l vo lume s.

  • L

iq uid stra tific a tio n:

  • He a t flo w o ve r liq uid-va po r inte rfa c e
  • He a t input thro ug h ta nk wa lls
  • L

iq uid ma ss is divide d in ho rizo nta l, disc re te la ye rs

  • He a t c o nduc tio n fro m la ye r to la ye r
  • Slo shing imple me nte d b y inc re a se d he a t tra nsfe r

c o e ffic ie nt b e twe e n la ye rs

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SLIDE 10

www.DL R.de / SART

  • Cha rt 10 > PMP > Va ne ssa Cla rk • E

UCASS > 01.07.2015

PMP Mo de lling Appro a c h

Mode ls

  • Ulla g e pre ssure re g ula tio n simula te d o ve r the missio n, with

simplifie d c o ntro l lo g ic e na c te d :

  • Pre ssure ma inta ine d within spe c ifie d o pe ra ting windo w thro ug h

ve nting o r the inje c tio n o f pre ssura nt g a s into ta nk ulla g e s (b a ng - b a ng style ).

  • Va lve dia me tre s, de la y time s c a n b e spe c ifie d.
  • Curre ntly, o nly ide a l g a s la ws a re c o nside re d, ho we ve r re a l

g a s la w imple me nta tio n is fo re se e n.

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SLIDE 11

www.DL R.de / SART

  • Cha rt 11 > PMP > Va ne ssa Cla rk • E

UCASS > 01.07.2015

PMP Mo de lling Appro a c h

Mode ls

  • Pre ssure ra te :
  • F

lo w ra te va po rize d pro pe lla nt (He rtz-K nudse n):

  • Ma ss pre ssura nt g a s:
  • I

nte rna l e ne rg y ulla g e o ve r time (no he a tflo w):

  • Ga smixture te mpe ra ture ra te :

              ′ ′ ′ ′ − ′ ′ ′ ′ ⋅ ′ ′ ⋅ + ′ ′ ⋅ + ′ ′ ⋅ − ⋅ ′ ′ ′ ′ = V V T T R m R m R m m V T p

pg pg vap vent vap

     ) ( ) (

pg vap vap sat i vap

m m m ratio ratio p p T R A m + = ⋅ ′ ′ − ⋅ ′ ′ ⋅ ′ ′ ⋅ ⋅ ⋅ =

−

) ( 2 1 10 6 π  Z T R V p m

pg pg

′ ′ ⋅ ′ ′ ⋅ ′ ′ ′ ′ ⋅ =

v vap c

m U T ′ ′ ⋅ ′ ′ ′ ′ = ′ ′   T c m T c m m U

v vap v vent vap

    ′ ′ ⋅ ′ ′ ⋅ − ′ ′ ⋅ ′ ′ ⋅ ′ ′ − ′ ′ = ′ ′ ) (

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SLIDE 12

www.DL R.de / SART

  • Cha rt 12 > PMP > Va ne ssa Cla rk • E

UCASS > 01.07.2015

PMP Mo de lling Appro a c h

Mode ls

  • Ulla g e vo lume ra te :
  • Ulla g e te mpe ra ture ra te :
  • Ulla g e pre ssure ra te :
  • Va po rise d pro pe lla nt vo lume ra te :

p pg vap prop vap gas liq wall gas wall prop pg p pg

c m m h m Q Q Q T T c m T ′ ′ ⋅ + ⋅ − − + + ′ ′ − ⋅ ′ ′ ⋅ = ′ ′

−

) ( ) (

, ,

     

liq vap drain

m m V ρ ′ ′ + = ′ ′    T R V m m T R V m m p

vent vap vent prop

′ ′ ⋅ ′ ′ ′ ′ ′ ′ − ′ ′ + ′ ′ ⋅ ′ ′ ⋅ ′ ′ ′ ′ − ′ ′ = ′ ′     p T R Z m m V

vent vap vap

′ ′ ′ ′ ⋅ ′ ′ ⋅ ′ ′ ⋅ ′ ′ − ′ ′ = ′ ′ ) (   

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SLIDE 13

www.DL R.de / SART

  • Cha rt 13 > PMP > Va ne ssa Cla rk • E

UCASS > 01.07.2015

PMP Mo de lling Appro a c h

slide-14
SLIDE 14

www.DL R.de / SART

  • Cha rt 14 > PMP > Va ne ssa Cla rk • E

UCASS > 01.07.2015

PMP Mo de lling Appro a c h

Pr

  • gr

am F unc tionality

I nputs:

  • Ge o me try inputs
  • Pro pe lla nt ma sse s (a sc e nt,

de sc e nt, re sidua l, re se rve )

  • T

a nk type a nd de sig n fa c to rs

  • T

a nk initia l the rma l c o nditio ns

  • Missio n histo ry inputs
  • Ulla g e pre ssure re q uire me nts
  • E

ng ine ma ss flo w ra te

  • F

lg ht pro file (lo a ds, e xte rna l te mpe ra ture , he a t fluxe s)

Outputs:

  • Sta tic o utputs:
  • T

a nk thic kne ss, le ng th a nd vo lume ,

  • T

a nk, line ma sse s,

  • Re sidua ls (fluid a nd g a se o us)
  • T

ime -de pe nda nt

  • Histo ry o f ma ss flo ws, ve lo c itie s,

pre ssure s, NPSPs, he a t tra nsfe r

  • Ulla g e te mpe ra ture s a nd

pre ssure s, e va po ra tio n

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SLIDE 15

www.DL R.de / SART

  • Cha rt 15 > PMP > Va ne ssa Cla rk • E

UCASS > 01.07.2015

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SLIDE 16

Sa turn-V a nd AS506

www.DL R.de / SART

  • Cha rt 16 > PMP > Va ne ssa Cla rk • E

UCASS > 01.07.2015

Ve hic le Ove r vie w

We rnhe r vo n Bra un; F

  • 1 E

ng ine s So urc e : NASA

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SLIDE 17

Sa turn-V a nd AS506

www.DL R.de / SART

  • Cha rt 17 > PMP > Va ne ssa Cla rk • E

UCASS > 01.07.2015

Ve hic le Ove r vie w

S-IC S-II S-IVB

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SLIDE 18

Sa turn-V a nd AS506

www.DL R.de / SART

  • Cha rt 18 > PMP > Va ne ssa Cla rk • E

UCASS > 01.07.2015

Ve hic le Ove r vie w

  • S-I

VB T hird Sta g e

9 x cold spheres for LOX pressurisation/re-pressurisation and LH2 re -pressurisation 2 x reserve ambient spheres for LOX re- pressurisation 6 x reserve ambient spheres for LH2 re- pressurisation

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SLIDE 19

Sa turn-V a nd AS506

www.DL R.de / SART

  • Cha rt 19 > PMP > Va ne ssa Cla rk • E

UCASS > 01.07.2015

Mission Ove r vie w

slide-20
SLIDE 20

Sa turn-V a nd AS506

www.DL R.de / SART

  • Cha rt 20 > PMP > Va ne ssa Cla rk • E

UCASS > 01.07.2015

Mission Ove r vie w

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SLIDE 21

Sa turn-V a nd AS506

www.DL R.de / SART

  • Cha rt 21 > PMP > Va ne ssa Cla rk • E

UCASS > 01.07.2015

Mission Ove r vie w

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SLIDE 22

Sa turn-V a nd AS506

www.DL R.de / SART

  • Cha rt 22 > PMP > Va ne ssa Cla rk • E

UCASS > 01.07.2015

Mission Ove r vie w

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SLIDE 23

Sizing Re sults

www.DL R.de / SART

  • Cha rt 23 > PMP > Va ne ssa Cla rk • E

UCASS > 01.07.2015

T ank L ayout and Plumbing

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SLIDE 24

Sizing Re sults

www.DL R.de / SART

  • Cha rt 24 > PMP > Va ne ssa Cla rk • E

UCASS > 01.07.2015

T ank L ayout and Plumbing

Internal and hydrostatic pressure used for structural sizing

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SLIDE 25

Sizing Re sults

www.DL R.de / SART

  • Cha rt 25 > PMP > Va ne ssa Cla rk • E

UCASS > 01.07.2015

Ullage E volutions

  • S-I

I

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SLIDE 26

Sizing Re sults

www.DL R.de / SART

  • Cha rt 26 > PMP > Va ne ssa Cla rk • E

UCASS > 01.07.2015

Ullage E volutions

  • S-I

VB

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SLIDE 27

Sizing Re sults

www.DL R.de / SART

  • Cha rt 27 > PMP > Va ne ssa Cla rk • E

UCASS > 01.07.2015

Pr e ssur ant Gas Consumption

slide-28
SLIDE 28

Sizing Re sults

www.DL R.de / SART

  • Cha rt 28 > PMP > Va ne ssa Cla rk • E

UCASS > 01.07.2015

NPSP

  • S-I

I

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SLIDE 29

Sizing Re sults

www.DL R.de / SART

  • Cha rt 29 > PMP > Va ne ssa Cla rk • E

UCASS > 01.07.2015

NPSP

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SLIDE 30

Co nc lusio n

www.DL R.de / SART

  • Cha rt 30 > PMP > Va ne ssa Cla rk • E

UCASS > 01.07.2015

F utur e Wor k

  • Co mpa riso n to e mpiric a l mo de ls

(ma ss; e stima tio n) a nd hig h-fide lity to o ls (2D – E c o Sim Pro ; CF D)

  • Co mmo na lity o f g e o me try mo de ls

with e .g . struc rtura l a na lysis pro g ra m

slide-31
SLIDE 31

Co nc lusio n

www.DL R.de / SART

  • Cha rt 31 > PMP > Va ne ssa Cla rk • E

UCASS > 01.07.2015

F utur e Wor k

  • I

mpro ve d ulla g e pre ssure c o ntro l lo g ic

  • E

xte nsio n to multi-fa c e te d pre ssurisa tio n syste ms

  • Re fine the rma l mo de ls:
  • He a t e xc ha ng e rs
  • He a t flux b e twe e n e le me nts:

sub me rg e d line s a nd pre ssura nt ta nks; e ng ine

  • E

c lipse , so la r b e ta -a ng le

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SLIDE 32

Co nc lusio n

www.DL R.de / SART

  • Cha rt 32 > PMP > Va ne ssa Cla rk • E

UCASS > 01.07.2015

  • Ove rvie w o f PMP pro vide d
  • AS506 suc c e ssfully mo de lle d de spite

the hig h syste m c o mple xity.

  • PMP c a n o nly b e utilise d b y

e xpe rie nc e d e ng ine e rs who a re a b le to kno wle dg e a b ly a da pt the input pa ra me te rs a nd se le c t the mo st re le va nt a nd re a listic pro g ra m

  • utputs a nd disc a rd tho se whic h a re

inva lid.

So urc e : NASA

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SLIDE 33

www.DL R.de / SART

  • Cha rt 33

va ne ssa .c la rk@ dlr.de

que stions?

> PMP > Va ne ssa Cla rk • Kic k Off> 23.02.2015

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SLIDE 34

Sizing Re sults

www.DL R.de / SART

  • Cha rt 34 > PMP > Va ne ssa Cla rk • E

UCASS > 01.07.2015

T ank L ayout and Plumbing

slide-35
SLIDE 35

Sizing Re sults

www.DL R.de / SART

  • Cha rt 35 > PMP > Va ne ssa Cla rk • E

UCASS > 01.07.2015

T ank L ayout and Plumbing

slide-36
SLIDE 36

Sizing Re sults

www.DL R.de / SART

  • Cha rt 36 > PMP > Va ne ssa Cla rk • E

UCASS > 01.07.2015

T ank L ayout and Plumbing

  • Struc tura l ma sse s:
  • Static loads o nly c o nside re d; dyna mic la unc h pa d, g ust o r g uida nc e a nd

c o ntro l syste m-drive n stiffne ss re q uire me nts te nd to b e the c ritic a l lo a ds.

  • Se c ond and thir

d stage e stimate s c lose r ; the o ve ra ll tre nd fro m the re fe re nc e

ma ss da ta :

  • Re duc e d struc tura l ma ss hig he r in the ve hic le due to de c re a sing lo a ds,
  • T

he five F

  • 1 e ng ine s a c t o n the S-I

C first sta g e with a fo rc e pe r unit a re a e xc e e ding the ta nk pre ssure s.

  • F

urthe rmo re , a t the e nd o f the first sta g e b urn, the thrust to b e tra nsmitte d thro ug h the e ntire e mpty sta g e to the S-I I L OX ta nk, whe re the la rg e st fra c tio n o f the sta g e ma ss a t this time po int is c e ntre d.

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SLIDE 37

Sizing Re sults

www.DL R.de / SART

  • Cha rt 37 > PMP > Va ne ssa Cla rk • E

UCASS > 01.07.2015

T ank L ayout and Plumbing

  • Sub se q ue nt a na lyse s fo r sma lle r sta g e s

sho we d a lo we r ma ss disc re pa nc y fo r ta nks (ma ximum ±12%) a nd line s (ma ximum

±12%)

  • Va lid ra ng e o f sta g e size s fo r ma ss

e stima tio ns ne e ds to b e de te rmine d thro ug h e xte nsive c a se studie s