cst-100 starliner: boeing's commercial crew program
TRANSCRIPT
The Space Congress® Proceedings 2016 (44th) The Journey: Further Exploration for Universal Opportunities
May 24th, 10:00 AM
CST-100 STARLINER: Boeing's Commercial Crew Program CST-100 STARLINER: Boeing's Commercial Crew Program
Danom Buck Boeing, Manager Manufacturing Engineering
Follow this and additional works at: https://commons.erau.edu/space-congress-proceedings
Scholarly Commons Citation Scholarly Commons Citation Buck, Danom, "CST-100 STARLINER: Boeing's Commercial Crew Program" (2016). The Space Congress® Proceedings. 6. https://commons.erau.edu/space-congress-proceedings/proceedings-2016-44th/presentations-2016/6
This Event is brought to you for free and open access by the Conferences at Scholarly Commons. It has been accepted for inclusion in The Space Congress® Proceedings by an authorized administrator of Scholarly Commons. For more information, please contact [email protected].
Copyright © 2016 Boeing. All rights reserved. Regan, 5/24/2016, Buck
Boeing’s Commercial Crew ProgramDanom Buck, Manager
Manufacturing Engineering
Space Congress
May 24, 2016
Copyright © 2016 Boeing. All rights reserved.
Copyright © 2016 Boeing. All rights reserved.
CST-100 Starliner Spacecraft• Flight-proven systems, high-technology readiness level
• Firm configuration established
Ground Processing Operations• Commercial Crew and Cargo Processing Facility modernized at NASA’s Kennedy Space Center
• Lean production based on Boeing’s commercial approach
• Integration testing and quality processes based on space shuttle and International Space Station approaches
United Launch Alliance Atlas V Rocket• More than 60 successes and counting!
• Proven rocket significantly reduces system risk
• Human-rating of Space Launch Complex 41 at Cape Canaveral Air Force Station in progress
Mission Operations• Integrated with the world’s experts on mission control: NASA Mission Operations Directorate
• Crew engagement through plan, train and fly phases
Mature System Design
Copyright © 2016 Boeing. All rights reserved.
Starliner Spacecraft
CLAM SHELL DESIGN
ALLOWS FOR EASY HARDWARE
INSTALLATION
SEATING FOR SEVEN
(5 CREW + 2 CREW EQUIVALENT
OF CARGO SHOWN)
FLEXIBLE CABIN DESIGN
ACCOMMODATES MIX OF CREW
AND CARGO
Cargo & Crew
Provisions
GLACIER
Launch
Abort
System
(LAS) Roll
Thrusters
LAS Escape
Thrusters
LAS
Pitch/Yaw
Thrusters
MMOD
Shields
Solar Panels
Thruster Doghouses
Vacuum Vent
Side Window
Forward Window
Ascent Cover
Radiators
Perforated Ring
CM/SM
Umbilical
Side Hatch
Forward Heat shield
Mature System Design
Copyright © 2016 Boeing. All rights reserved.
LEGEND
BLACK = HERITAGE
BLUE = NEW SYSTEMS
Emergency
Egress
System
Crew Access
Arm and
White Room
Environmental Seal
Crew
Access
Tower
LAS Escape Thrusters
Launch Vehicle
Adapter
Centaur Forward
Adapter
Common
Centaur
Centaur Aft Stub
Adapter
400 Series
Interstage
Adapter
Solid Rocket
Boosters (2)
Aft Transition
Structure
Heat Shield RD-180 Engine
CST-100 Starliner
Emergency Detection
System and Software
Dual Engine
Centaur
Two RL-10A-4-2
Atlas Booster
Atlas V Launch Vehicle
Mature System Design
Copyright © 2016 Boeing. All rights reserved.
Nationwide Supplier Base
AZ
CO
AL
CT
FL
TX
NY
OR
OK
MN
MI
DE
NJ
NH
OH
MA
KS
L.A./OC areaAerojet Rocketdyne(Canoga Park)Adept Fasteners(Valencia)Airborne Sys(Santa Ana)AiTech(Chatsworth)Arrow Elec(Foothill Ranch)Aero PacificCoast Aerospace(Placentia) Aireps, IncCanyon CompositesCytecAstrotekHQ Machine(Anaheim)Coastal Component(Orange)Avnet Coast Composites(Irvine)Curtiss Wright (City of Industry)DRSCypress)Expanded Rubber(Rancho Dominquez)
Central ColoradoUnited Launch Alliance
(Centennial)Special Aerospace Services
Technology Applications(Boulder)
ABSL Space Products(Longmount)
Phoenix AZ AreaAvnet
(Phoenix)Gen Dynamics
(Scottsdale)BROAD REACH
SAFESystems 3
(Tempe, AZ)
Gen Dynamics (Bloomington)
Aerospace Fabrication(Farmington)
Spincraft(N. Billerica)
David Clark(Worcester)
OATK(Beltsville)
Ensign Bickford(Simsbury)
Ultra MSI(Wallingford)
Hamilton Sundstrand(UTAS)
(Windsor Locks)
ILC Dover(Frederica)
Honeywell(Clearwater)
EO Imaging(W. Melbourne)
Samson Metal and Machine (Lakeland)
Paragon(Tucson)
Houston, TXAnadarko
Barrios TechnologyBastion Technologies
Cimarron SoftwareGeoControl
Frontier Electronics (Stillwater)
Electro Enterprises (Oklahoma City)
San Diego, CAAEM INCL-3 Comm
Performance PlasticsRayotek Scientific
Sanders CompositesVanguard
Haigh Farr(Bedford)
ARDE(Carlstadt)
DJ Eng(Augusta)Galaxy
(Winfield)
All Points Logistics
(Huntsville)Cornerstone Supply
Wildwood Electronics(Madison)
Emerging Power(Hackensack)
Marotta (Montville)
Magellan Aerospace (Corona)
Niagra Thermal(Niagra Falls)Calspan Corp
(Buffalo)Amphenol
(Sidney)Taylor Devices
(No. Tonawanda)
Visioneering(Auburn Hills)
Mainthia(Cleveland)
WA
Aerojet RocketdyneCrane Electronics
(Redmond)Janicki Industries(Sedro-Wooley)
Near Space(Tillamook)
Micropac(Garland)
TTI(Ft. Worth)
WB Industries(O’Fallon)
Major Tool and Machine
(Indianapolis)
Zodiac Data Sys(Alpharetta)
L.A./OC cont’d. KAP Mfg(San Dimas)Millworks Precision (Corona)OATK(Commerce)Rubbercraft(Long Beach)Solara Eng(Sun Valley)Stanford Mu (Carson)Tayco(Cypress)AAE Aerospace Tri-Models(Huntington Beach)Qual Pro(Gardena)VaccoAMRO (South El Monte)VotawPrecision Tube (Santa Fe Springs)
MO
GA
IN
MDCA
ASC (Santa Barbara)
Delta Microwave(Oxnard)
Pacific Scientific (Hollister)
Ares Corp(Burlingame)
Packaging Sys(Santa Clara)
Wesco(Santa Clarita)
Applied Aerospace (Stockton)
Copyright © 2016 Boeing. All rights reserved.
Structural Test Article build-up in Commercial Crew and Cargo Processing Facility
at Kennedy Space Center, Florida
Spacecraft 1 hardware progressing across supply base and arriving
to Commercial Crew and Cargo Processing Facility at Kennedy Space Center, Florida
Build Progress
Copyright © 2016 Boeing. All rights reserved.
Starliner performs first contingency water drop qualification
test at Langley Research Center, Virginia
Crew Access Arm and White Room undergoing testing
through various lighting conditions in Oak Hill, Florida
NASA and Det 3 rehearse rescue
and recovery operations with Starliner
Test Progress
Copyright © 2016 Boeing. All rights reserved.
Astronauts run through simulations on
Crew Part-Task Trainers built in St. Louis
Astronaut Ricky Arnold visits ECLSS
manufacturer in Connecticut
Astronaut Megan McArthur visits LIDAR
manufacturer in Santa Barbara, California
Astronauts receive Atlas V familiarization training
with United Launch Alliance in Decatur, Alabama
Astronaut Training and Supplier Visits
Copyright © 2016 Boeing. All rights reserved.
Test Location Primary Purpose
Structure
Verification
Testing
NASA Kennedy
Space Center,
Florida & Huntington
Beach, California
• CST-100 structure verification• Modal survey• Structures loading for critical load
conditions• Structural integrity• Ordnance-actuated device shock
levels• Separation system performance• FEM validation
Service Module
Hot Fire Test
NASA White Sands
Test Facility, New
Mexico
• Demonstrate integrated propulsion system
performance and system dynamics
Ground
Verification
Testing /
Environmental
Qualification
Testing
NASA Kennedy
Space Center,
Florida & El
Segundo, California
• Perform vehicle-level environmental
verification testing and system-level
non-chamber qualification:
• Verify system performance
verification
• Electromagnetic compatibility
• Thermal vacuum and acoustic
environments
What’s Next? Qualification Test Campaign
Structure Verification Testing
Copyright © 2016 Boeing. All rights reserved.
Test Location Primary Purpose
Full-Scale Crew
Module Drop Tests
Dugway Proving
Ground, Utah &
NASA Langley
Research Center,
Virginia
• Verify spacecraft landing impact attenuation performance
• Verify parachute systemperformance, forward heat shield separation and base heat shield jettison across various nominal and off-nominal conditions
Integrated System
Verification Test
(ISVT)
Multiple • Demonstrate the integrated
spacecraft / space station
performance
End-to-End (E2E) Multiple • Complete crew transportation
system end-to-end connectivity and
integration across the segments and
external interfaces
Pad Abort Test (PAT) NASA White Sands
Test Facility, New
Mexico
• Demonstrate the abort system
performance
Orbital & Crew Flight
Tests
(OFT, CFT)
Multiple • Demonstrate complete crew
transportation system orbital mission
– uncrewed flight test and crewed
flight test to space station
Full-Scale Crew Module Drop Tests
What’s Next? Qualification Test Campaign
Copyright © 2016 Boeing. All rights reserved.
Test Articles
Structural Test Article Crew Module – Structure Verification Testing; Training Article
Structural Test Article Service Module – Structure Verification Testing
Service Module – Hot Fire Testing
* Test Articles in flow in C3PF at Kennedy Space Center *
Spacecraft 1
Crew Module – Ground Verification Testing; Pad Abort Test
Service Module – Ground Verification Testing; Pad Abort Test
* Spacecraft 1 hardware in C3PF at Kennedy Space Center with more on the way *
Spacecraft 2
Crew Module – Environmental Qualification Testing; Crew Flight Test; PCM-2
Service Module – Environmental Qualification Testing; Crew Flight Test
* Spacecraft 2 hardware in production via supply base *
Spacecraft 3
Crew Module – Orbital Flight Test; PCM-1
Service Module – Orbital Flight Test
* Progressing through unit and subsystem build via supply base *
Starliner Traffic Model
Copyright © 2016 Boeing. All rights reserved.